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Copyright 2015 © Lockheed Martin
Additive Manufacturing and the Factory of the Future
Slade Gardner, PhD
Lockheed Martin Space Systems Company
Copyright 2015 © Lockheed Martin
ADDITIVE MANUFACTURING For Defense and Gov. Symposium 14 May 2015
Copyright 2015 © Lockheed Martin
A Globally Oriented Company Providing Security Systems, Solutions and Services to Governments Around the World
Aeronautics Integrated Systems & Global Solutions
Space Systems
Mission Systems & Training
Missiles & Fire Control
Copyright 2015 © Lockheed Martin
Lockheed Martin Space Systems Company: Organized to address an array of critical mission areas
Strategic and Missile Defense
Civil Space
Advanced Technology Center
Military Space
Special Programs
Commercial Space
Each Line of Business focuses on specific mission areas
Copyright 2015 © Lockheed Martin
Juno mission
Copyright 2015 © Lockheed Martin
Juno mission
Goals and Overview • Understand the origin and evolution of Jupiter • Origin of solar system and planetary systems being discovered around other stars • 32 polar orbits will extensively sample Jupiter’s full range of latitudes and longitudes • Elliptical orbit swings below radiation belts to minimize radiation exposure • Global maps of the gravity, magnetic fields, and atmospheric composition • in-situ and remote sensing observations • Explore polar magnetosphere and determine what drives Jupiter’s remarkable auroras
August 5, 2011 July 4, 2016 October 9, 2013
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Additive Manufacturing for Juno
Wave Guide Brackets Ti 6Al-4V Secondary structure Several parts of a few designs
Electron Beam Melting
Demonstrated 2X savings in cost Demonstrated 2X schedule improvement Confidence testing for mech properties Equivalent properties to billet machined Confidence testing for fatigue Microstructure analysis
Copyright 2015 © Lockheed Martin
SSC 3D Printing Advancements
• Tooling/Ground Equipment – NIRCam – Orion – Fleet Ballistic Missile (FBM) – Solar Array
• Engineering Development – A2100TR shear tie fittings – Orion gimbal – Military Support Program (MSP) fittings – Composite panel clips & inserts – Propulsion tanks
• Flight Articles – Juno secondary structure – PIRANHA camera bracket – Osiris-Rex strut (planned) – A2100TR strut (planned)
From Tooling… to Prototypes… to Flight Hardware… Significant Cycle Time and Cost Reduction
Copyright 2015 © Lockheed Martin
Additive Manufacturing of Large Metallic Primary Load Structures
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Titanium Propellant Tank Dome
IRaD funded manufacturing demonstration • 16” scale demo manufacturing study
• Baseline tank domes are forged titanium
• Each A2100 has 5 or more tanks (10 domes)
• Laser scan of DM part ‘bulls-eye’ on deposition
• 2013 – Proof test DM tank – pressure test
Advantages
• DM Accelerates schedule
• Baseline forged dome: 12-18 Mo lead time
• DM Dome Preform was made in 3 hours
• DM Dome is ~50% cost of forged dome
• Baseline forging limitation 46” diameter
• DM Dome does not have same size limitation
Example A2100-type Propulsion System
Ti Tanks (5)
Base Stock
Direct Mfg Material
Copyright 2015 © Lockheed Martin
Titanium Propellant Tank
Rough Machined Ti Domes Heat Treatment and Quench Heat Treated Domes (alpha case)
Final Machined Titanium Domes
Propulsion Tank Hydrostatic Test • MEOP 450 psi – PASS
• 12 Cycles at 1.25X MEOP (565 psi) - PASS
• 50 Cycles at MEOP (450 psi) – PASS
• Burst Test 2X+ MEOP
Copyright 2015 © Lockheed Martin
Building the Factory of the Future
Copyright 2015 © Lockheed Martin
Additive Manufacturing of Polymers and Composites
Copyright 2015 © Lockheed Martin
Fused Deposition Modeling (FDM)
Rapid Prototyping Equipment & Method • Thermoplastic polymer – ‘3D Printing’
• Precision structures – high tolerance – feature detail
• Good mechanical properties for RP
• Fast turn around – inexpensive path to parts
Over 100 Flying Parts
Duct for X-plane UAV fuel tank
Fuel tank assembled UAV Tail and
control UAV nose cone
Inlet (R&D)
CM/SM Umbilical Mock-Up
First to flight 2004
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Extension of FDM with Materials
Custom materials ready for FDM
Materials Formulation Extrusion - Resins, Fiber/Fillers, Specialty
FDM Filament Single Screw Extrusion 0.070” Diameter Profile
Analysis PP & Capillary Rheology Microscopy (SEM, AFM)
Evaluation Coupon Fab Mech & Phys Analysis
• New formulations made and tested quickly • Innovative atmosphere – design revolution • Pellets to test coupons in same day • Rapid cycle allowed development of APEX
Copyright 2015 © Lockheed Martin
First Large Scale Additive Polymer System
–Pointwise Composition Control - deposition of materials/properties where needed, when needed – Out-of-Chamber - localized heat source - build envelop size not limited (adaptable to gantry) – On-the-fly - blend compounding & material change-over – Tailored thermoplastic composites - broad material selection - performance attributes
Multi-hopper Polymer Drying/Vacuum Transfer System Blender/Formulator/Feeder System Robot-Polymer Extruder/CAD-CAM Controls/Deposition System
Materials: Polymers, reinforcements, and additives - dried for extrusion processing
Formulation: Automated transfer of materials and components pre-blended for extrusion processing
Deposition: Pre-blended recipe – transferred to extruder for deposition of structure
1 2 3
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LM Large Additive Polymer
Rapid model or prototype Tooling fixtures, jigs, locators etc… Part simulations for manufacturing assembly Demonstrated for children and parents at USA SEF STEM event
Copyright 2015 © Lockheed Martin
Two Robot Additive Cluster
Additive Composite • CF/ABS process development material
• High performance materials
• Composition control
Subtractive Machining • Surface milling
• Cutout/machining
Process Monitoring • Vision system
• Thermal history
Inspection/Measurement • Laser distance probe
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System Build and Check Out
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Symposium Demonstrations
Defense Manufacturing Conference – San Antonio, TX – Dec 2014 DMDII Grand Opening – Goose Island, IL – May 2015 RAPID – Long Beach, CA – May 2015 Defense Manufacturing Conference – Phoenix, AZ – Dec 2015
Copyright 2015 © Lockheed Martin
Multi-Robot Additive Cluster
Focus: bus, substructure and mechanisms
Type:
Copyright 2015 © Lockheed Martin