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Fluid Power Applications for Emerging Trends in Additive Manufacturing
Lonnie Love Manufacturing Systems Research Manufacturing Demonstration Facility Oak Ridge National Laboratory
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Outline
• Background – ORNL’s push in manufacturing
• Bringing $B of scientific tools to manufacturing – Focus on Additive Manufacturing and Carbon Fiber
• Impact on Efficiency – Weight reduction – Mesoscale valves
• Zero tare flow, digital and thermal poppets – Creative designs blending additive/carbon fiber and fluid power
• Role in workforce development – Using AM to drive kids to STEM – Partnering with America Makes (NAMII) and FIRST
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DOE’s first Manufacturing Demonstration Facility at Oak Ridge National Laboratory
A DOE-funded facility promoting broad and rapid dissemination of advanced manufacturing technologies
ORNL’s Carbon Fiber Technology Facility A DOE-funded facility for demonstrating advanced technology scalability and producing market-development volumes of prototypical carbon fiber Production capacity:
25 tons/yr fiber from multiple precursors in various forms
Additive Manufacturing enabling product customization, improved
performance, multifunctionality and lower overall manufacturing costs
Carbon Fiber and Composites enabling widespread deployment in high-volume,
cost-sensitive energy applications
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Additive Manufacturing (AM)
“Additive Manufacturing will become the most important,
most strategic, and most used manufacturing technology ever.”
Wohlers 2012
• Increased Complexity • Less Material Scrap • Shorter Design Cycle • Reduced Part Count • Faster • Cheaper • Better!
CAD Model to Physical Part
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Additive Manufacturing (AM) MDF Thrust Area
Leveraging key resources at ORNL to accelerate technology implementation • Developing advanced materials
– Titanium alloys, Ni superalloys, stainless and ultra high-steels
– High-strength, carbon-reinforced polymers
• Implementing advanced controls – In-situ feedback and control for rapid certification and
quality control
• Understanding material properties and geometric accuracy
• Exploring next-generation systems to overcome technology barriers for manufacturing – Bigger, Faster, Cheaper
– Integrating materials, equipment and component suppliers with end users to develop and evolve the supply chain
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• Developing in-situ characterization, feedback and control
• Precision melting of powder materials
• Processing of complex geometries not possible through machining
Electron Beam Melting (4)
• Simultaneous additive and subtractive process for manufacturing complex geometries
• Solid-state process allows embedding of optical fibers and sensors
Ultrasonic Additive Manufacturing (1)
• Site-specific material addition
• Application of advanced coating materials for corrosion and wear resistance
• Repair of dies, punches, turbines, etc.
Laser Metal Deposition (1)
• High Resolution • Unsintered support powder (easy removal)
• Wide variety of materials
Laser Powder Bed (1)
• High deposition rate • Large volume • Metal, polymer and ceramic feedstock
Laser Sintering (2)
9 Metal
Working with AM equipment providers to develop high-performance materials, low-cost feedstocks, processing techniques and in-situ characterization and controls to enable broad dissemination of technologies
Current Equipment
Additive Manufacturing (AM)
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• Developing in-situ characterization, feedback and control
• New high strength materials
• Increased z-strength
Fused Deposition Modeling (4)
• Multi-materials • Very high resolution
Stereolithography(1)
• Enormous growth • Low-cost (<$2K) • Open source so easy
for new material and control development
Desktops (15)
20 Polymer Current Equipment
Additive Manufacturing (AM)
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Leveraging Billions of Dollars of R&D Science to Application
Critical to widespread adoption of technology
Profilometry map illustrating distortion
• Advanced materials and processing to expand available materials
• Sensing and controls to provide reliability • Neutron science and advanced microscopy to
understand material properties • High performance computing to build models
to enable future design and processing tools
Laser AM creates large residual
stress leading to distortion
laser AM of turbine blade
Understanding link between residual stress and additive manufacturing
Utilizing neutron science to impact industry
turbine blade
Reconstructed image using neutron tomography
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E-beam approach: Hydraulic hand • Additive processes enable integrated pump, fluid passages and pistons into a
structure with mesh for weight reduction • Titanium hand made using E-beam fusion (operating pressure 3000 psi)
Curved fluid passages
Pistons integrated into structure
Integrated motor and pump
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Mechanical considerations • Mechanical Strength
– Hold to well over 6000 psi at 0.020” wall thickness on 0.125” tube
– Wrought Mechanical properties, even for 0.015” AM mesh
– Polish internal cavities
No finishing Aggressive finishing
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Mesh structures for weight reduction
• Blending hydraulics and AM
• Less mass means – Less material – Less energy – Faster build – Lower cost
Solid palm weighing 857 grams. Meshed palm weighing 178 grams
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Office of Naval Research: Underwater robotics • Completely printed arm
– Target is neutrally buoyant without any floatation devices • Shell structures for weight reduction (0.030” wall thicknesses)
• Total weight of 60” long arm is 25 lbs.
– Integrated hydraulics and electronics (nothing penetrates the skin) – No hoses, fluid passages integrated into structure – Anthropomorphic design
• 7 Degrees of freedom • Antagonistic actuation at each joint • Each joint has 180 degrees of rotation
– Custom thermal valves for energy efficiency
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ONR underwater robotics
Involute cam joint
Barrel cam joint
Design rule: Provide 0.030” to 0.050” excess material on bearing surfaces and piston bores.
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Mesoscale valves • High pressure (>3000 psi), low flow (<10 mL/min) control valves • Three designs all based on poppet valves
– Direct flow control via liquid cooled SMA • Zero tare flow • Independent chamber control (regeneration) • Low bandwidth (< 10 Hz), but low-cost fabrication/assembly • Very mature (have manufactured hundreds, implemented on underwater robot)
– Digital flow control • Zero tare flow • High bandwidth (> 200 Hz) • Still needs maturation
– Two stage digital valve • High flow rate via two stage poppet • Digital valve modulates pressure in large poppet
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Carbon Fiber FDM Composites
CF-ABS
2x strength
4x stiffness
ABS
CF-ABS
• Compounded filament printed on Solidoodle 3 • 10-15% CF by weight
Dramatically reduced curl
Lindahl ACCE (2013)
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• Collaboration between ORNL, Lockheed Martin and Equipment Manufacturer – Materials – low CTE, high strength materials – Deposition – new methods of deposition and
control – Multiple-robot coordination (8’ x 8’ x 8’ gantry,
Kuka Robot) • Pellet-to-Part: Enables manufacturing of large
components using pelletized feed.
Big Area Additive Manufacturing (BAAM)
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Big Area Additive Manufacturing (BAAM)
Large scale deposition system • Unbounded build envelope
• High deposition rates (~20 lbs/h)
• Direct build components
• Tools, dies, molds
Carbon fiber material reduces warping out of oven
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Out-of-oven • Manufacturing carbon fiber reinforced
materials – Shows increased strength and significant
reduction in distortion – Preliminary testing on in-situ post-processing
was successful
• Making sample parts for NavAir Cherry Point.
• Exploring new materials – CF ABS, CF Ultem, PEKK…
• For surface finish, have integrated fly cutter
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FIRST Robotics Competition 2011–2012 teams now at work • Founded by Dean Kamen
(Segway inventor): For Inspiration and Recognition of Science and Technology
• Goal: Inspiring youth to be science and technology leaders
• Opened ORNL MDF to work with 8 area high schools
• Over 50 mentors and teachers • Over 200 students • Over $200K in industrial
support (Stratasys, DOE AMO, NFPA, Bimba )
• All schools learn to use AM • 2012 Smoky Mountains Regional
Competition • Hardin Valley Academy
Engineering Excellence Award (first completely AM Robot!)
• Oak Ridge High School Top Rookie All Star Award & Nationals Contender
• Webb High School Woodie Flowers Finalist Award
• Knoxville Catholic High School and Seymour High School Ranked in the Top 5
The future of manufacturing? STEM - High School Robotics Teams
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ORNL, FIRST and HVA • Using FIRST as a platform to teach next generation of engineers about
manufacturing – Shown to over 200 companies, 1000 visitors – Students took to NAMII kickoff and DMC
Five students designed system
Shooter signed by policy makers
This is the highlight
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Hybrid Assemblies
• First Robotics Team #3824 – Hardin Valley Academy – RoHawktics – Sponsored by ORNL Manufacturing Demonstration Facility
(MDF) • Hybrid Assembly
– FDM Fittings – Pultruded Rods – Filament winding
• Benefits – Additive is great at relatively smaller more complex – Carbon fiber is great at long, simple, light weight, high
strength structures – Combining provides strengths of both technologies
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First Robotic Team #3824 • Application
– Robot Chassis – Stiff/light weight
• Solution – FDM light weight end pieces with critical
interfaces – Pultruded carbon rods for spanners – Filament wound for bonding and
strength/stiffness • Results
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Part Length AM Only Hybrid
Fab Time Weight Fab Time Weight
Long Beam 54” 90 hrs 14.64 lbs 15.5 hrs 3.86 lbs
Short Beam 21” 24 hrs 7.44 lbs 8.25 hrs 1.77 lbs
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Team #3824, supported by DOE’s MDF, wins award for most 3D printed parts on robot, ranks #10 in division
Science, Technology, Engineering & Mathematics (STEM) DOE’s MDF Partners with NAMII to Showcase Additive Manufacturing at 2013 FIRST Championship in St. Louis
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Conclusion • Many opportunities for fluid power industry in advanced
manufacturing • Additive for:
– Weight reduction – Integration of hydraulics with structure
• Existing program with Aerovalve (Ellen Mell) – New carbon fiber reinforced polymers for wider spectrum of
applications
• Low cost carbon fiber – Target $5/lb – Integration with feedstock or development of hybrid systems
• Importance of STEM – ORNL and NAMII partnering with FIRST