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NSRP Robotic Arc DED AM ndashAdvanced Capabilities Workshop
Robotic DED Test-beds for Collaboration
1Approved for Public Release Distribution is Unlimited
Dennis Harwig EWISenior Tech Leader
bull Much of the content presented was developed in the National Shipbuilding Research Program ndash Advanced Shipbuilding Enterprise (NSRP-ASE) Research Announcement (RA) Project 2019-375-004
Acknowledgement
2Approved for Public Release Distribution is Unlimited
NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
Project TeamEWI ndash Project PINavus AutomationAustal USANSWCCDABS
Objectivesbull Convert multiple robotic weld systems to DED systemsbull Design standardized large-scale gantry DED systembull Develop digital data workflow processes bull Develop advanced training materials - workforce bull Demonstrate representative qualifications bull Provide standardized equipment amp services bull Build prototypes of increasing complexitybull Identify implementation opportunities
Reducing barriers to implement DED AM
Project Period June 2019 ndash July 2021
3Approved for Public Release Distribution is Unlimited
DED Deposition Rate vs Resolution
Courtesy Boeing
Decreased Resolution
Incr
ease
d D
epos
ition
Rat
eDEDCapability
DED AM Double-sided integrated build platform (DS-IBP) used to balance residual stresses and increase productivity
4Approved for Public Release Distribution is Unlimited
Courtesy Autodesk
Autodesk PowerMill Additive ndash DED Build Categories
5Approved for Public Release Distribution is Unlimited
bull Basic amp Adv PowerMill DED AM Launchedbull Autodesk Authorized Training Center (pending)
bull Multiple test-bed systems - training process prototypingbull IR-based preheat amp inter-pass control
bull Robot DED AM systems availablebull 7-axis Motoman Fronius Arc DED Systembull 8-axis Motoman Powder Laser DED Systembull (2) 8-axis OTC Arc DED Systemsbull Dual 8-axis Genesis Fanuc MP-Arc DED System bull 9- amp 11-axis Navus ABB MP-Arc DED Gantry
bull Additional robotic DED AM systems plannedbull 9-axis Cloos MP-Arc DED System bull 6-axis Motoman Wire Laser DED System
Robotic DED Training amp Build Test-beds
Shared EWIOSU Systems (MP) Multi-process torch changer
6Approved for Public Release Distribution is Unlimited
Robotic Arc DED SystemsMotoman - FroniusCMTGMA-PGMA
CloosMotion GMA-P amp T-GMA
Navus ABB Gantry(Multi-process DED)
OTC-Daihen GMA-PGMA
OTC-DaihenSyncroFeed
Fanuc - Lincoln GMA-PGMATW-GMA
Fanuc - Fronius amp SBI(CMTGMA-P amp Plasma)
7Approved for Public Release Distribution is Unlimited
Genesis Fanuc Robotic Arc DED Systembull Dual-arm system
bull Primary welding deposition armbull Fronius TPS 5000CMT
bull CMT GMA-P GMAbull Change waveform conditions based on build features
bull Second arm ndash flexibilitybull SBI Plasma Arc DED System (being acquired)
bull Dual-wire feedbull Auxiliary equipment scanners grinding inspection
bull Automated inter-pass temperature control bull Two axis positioner capable of building single- or
double-sided build platform structures
8Approved for Public Release Distribution is Unlimited
bull 350 Amp ACDC Invertor Systembull 290 Amp DC 100 Duty
bull Multifunctional plasma system bull Plasma joining and hardfacingbull Plasma spot weldingbull Plasma powder weldingbull Plasma brazingbull TIG welding (GTAW)bull Plasma metal deposition (directed energy
deposition) with wire and powder bull Singledual hot wire amp powder feed
SBI Plasma Arc DED
9Approved for Public Release Distribution is Unlimited
EWIOSU OTC Robotic DED SystemsSynchro-feed100 CO2No Spatter
bull Two (2) OTC 8-axis GMA-P DED Systemsbull Synchro-Feedtrade Robotic Weldingbull Welbee WB-P500L power sourcebull Inter-pass temperature control bull Two axis positioner
bull Current Ma2JIC focus bull ER5183 GMA-P DEDbull Walls amp Block Proceduresbull 6- amp 8-axis Builds
10Approved for Public Release Distribution is Unlimited
EWIOSU Cloos Robotic Multi-process DED Systembull Dual Process Test-bed
bull Motion GMA and Tandem GMAbull High melting rate T-GMA controlbull Laser depth amp IR sensorsbull 2-ton capacity double-sided builds
bull Feature - cooling rate ndash property controlbull Cryogenic cooling support processbull Maximum duty and build rate
bull Adapt waveform conditions based on build conditions to max productivity and control properties
bull Current Ma2JIC focusbull Adv High Strength Steels
11Approved for Public Release Distribution is Unlimited
Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
12Approved for Public Release Distribution is Unlimited
Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process
bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle
bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of
quality control and part certification technologies
bull Unique resource for prototyping metal DED AM structures and components
System available for large-scale DED application development
Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
13Approved for Public Release Distribution is Unlimited
Welding Processesbull Welding systems
bull Fronius TPS 500i CMT system
bull Fronius WF 60i RobactaDrive CMT Torch
bull Fronius CU 1100i Water Cooler
bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water
Coolerbull STT Power Wave module
Large-scale Multi-process Robotic Gantry DED System
bull Binzel Torch Maintenance Stationbull Services Both Torch Types
bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot
Base
14Approved for Public Release Distribution is Unlimited
Metalworking processesbull PushCorp 5-HP spindle
bull AFD340 Active Compliance Device
bull BT30 Tool Changing Stationbull Grinding burring brushing
bull Miller Coolmate 3 Water Cooler
bull ATI Tool Changer
Large-scale Multi-process Robotic Gantry DED System
15Approved for Public Release Distribution is Unlimited
Monitoring Sensorsbull Synchronized weld parameter data
acquisition bull Melt Tools camera
bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal
Imaging Camerabull Non-contact measurement of surface
temperature from -4degF to 4442degFbull Inter-pass Temperature control
bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and
documentation during DED AMbull Used with both welding systems
bull Mount for Binzel Torchbull Mount for Fronius Torch
Large-scale Multi-process Robotic Gantry DED System
16Approved for Public Release Distribution is Unlimited
bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis
bull Large-scale single-sided buildsbull Large scale double-sided builds
bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing
bull DED Welding Cladding Machining
Pre-Engineered Large-scale Robotic Gantry DED Systems
17Approved for Public Release Distribution is Unlimited
bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)
bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)
bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI
bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze
bull Demonstrated single-sided integrated build platform standard qualification builds
bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems
New Capabilities - Summarybull Developed basic PowerMill Robotic DED training
seminarbull Developed advanced PowerMill robotic DED training
programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing
complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-
scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support
processes (thermal mgmt auto-maintenance quality monitoring amp control etc)
18Approved for Public Release Distribution is Unlimited
bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)
bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals
bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling
Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance
bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station
bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management
bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET
19Approved for Public Release Distribution is Unlimited
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
bull Much of the content presented was developed in the National Shipbuilding Research Program ndash Advanced Shipbuilding Enterprise (NSRP-ASE) Research Announcement (RA) Project 2019-375-004
Acknowledgement
2Approved for Public Release Distribution is Unlimited
NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
Project TeamEWI ndash Project PINavus AutomationAustal USANSWCCDABS
Objectivesbull Convert multiple robotic weld systems to DED systemsbull Design standardized large-scale gantry DED systembull Develop digital data workflow processes bull Develop advanced training materials - workforce bull Demonstrate representative qualifications bull Provide standardized equipment amp services bull Build prototypes of increasing complexitybull Identify implementation opportunities
Reducing barriers to implement DED AM
Project Period June 2019 ndash July 2021
3Approved for Public Release Distribution is Unlimited
DED Deposition Rate vs Resolution
Courtesy Boeing
Decreased Resolution
Incr
ease
d D
epos
ition
Rat
eDEDCapability
DED AM Double-sided integrated build platform (DS-IBP) used to balance residual stresses and increase productivity
4Approved for Public Release Distribution is Unlimited
Courtesy Autodesk
Autodesk PowerMill Additive ndash DED Build Categories
5Approved for Public Release Distribution is Unlimited
bull Basic amp Adv PowerMill DED AM Launchedbull Autodesk Authorized Training Center (pending)
bull Multiple test-bed systems - training process prototypingbull IR-based preheat amp inter-pass control
bull Robot DED AM systems availablebull 7-axis Motoman Fronius Arc DED Systembull 8-axis Motoman Powder Laser DED Systembull (2) 8-axis OTC Arc DED Systemsbull Dual 8-axis Genesis Fanuc MP-Arc DED System bull 9- amp 11-axis Navus ABB MP-Arc DED Gantry
bull Additional robotic DED AM systems plannedbull 9-axis Cloos MP-Arc DED System bull 6-axis Motoman Wire Laser DED System
Robotic DED Training amp Build Test-beds
Shared EWIOSU Systems (MP) Multi-process torch changer
6Approved for Public Release Distribution is Unlimited
Robotic Arc DED SystemsMotoman - FroniusCMTGMA-PGMA
CloosMotion GMA-P amp T-GMA
Navus ABB Gantry(Multi-process DED)
OTC-Daihen GMA-PGMA
OTC-DaihenSyncroFeed
Fanuc - Lincoln GMA-PGMATW-GMA
Fanuc - Fronius amp SBI(CMTGMA-P amp Plasma)
7Approved for Public Release Distribution is Unlimited
Genesis Fanuc Robotic Arc DED Systembull Dual-arm system
bull Primary welding deposition armbull Fronius TPS 5000CMT
bull CMT GMA-P GMAbull Change waveform conditions based on build features
bull Second arm ndash flexibilitybull SBI Plasma Arc DED System (being acquired)
bull Dual-wire feedbull Auxiliary equipment scanners grinding inspection
bull Automated inter-pass temperature control bull Two axis positioner capable of building single- or
double-sided build platform structures
8Approved for Public Release Distribution is Unlimited
bull 350 Amp ACDC Invertor Systembull 290 Amp DC 100 Duty
bull Multifunctional plasma system bull Plasma joining and hardfacingbull Plasma spot weldingbull Plasma powder weldingbull Plasma brazingbull TIG welding (GTAW)bull Plasma metal deposition (directed energy
deposition) with wire and powder bull Singledual hot wire amp powder feed
SBI Plasma Arc DED
9Approved for Public Release Distribution is Unlimited
EWIOSU OTC Robotic DED SystemsSynchro-feed100 CO2No Spatter
bull Two (2) OTC 8-axis GMA-P DED Systemsbull Synchro-Feedtrade Robotic Weldingbull Welbee WB-P500L power sourcebull Inter-pass temperature control bull Two axis positioner
bull Current Ma2JIC focus bull ER5183 GMA-P DEDbull Walls amp Block Proceduresbull 6- amp 8-axis Builds
10Approved for Public Release Distribution is Unlimited
EWIOSU Cloos Robotic Multi-process DED Systembull Dual Process Test-bed
bull Motion GMA and Tandem GMAbull High melting rate T-GMA controlbull Laser depth amp IR sensorsbull 2-ton capacity double-sided builds
bull Feature - cooling rate ndash property controlbull Cryogenic cooling support processbull Maximum duty and build rate
bull Adapt waveform conditions based on build conditions to max productivity and control properties
bull Current Ma2JIC focusbull Adv High Strength Steels
11Approved for Public Release Distribution is Unlimited
Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
12Approved for Public Release Distribution is Unlimited
Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process
bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle
bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of
quality control and part certification technologies
bull Unique resource for prototyping metal DED AM structures and components
System available for large-scale DED application development
Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
13Approved for Public Release Distribution is Unlimited
Welding Processesbull Welding systems
bull Fronius TPS 500i CMT system
bull Fronius WF 60i RobactaDrive CMT Torch
bull Fronius CU 1100i Water Cooler
bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water
Coolerbull STT Power Wave module
Large-scale Multi-process Robotic Gantry DED System
bull Binzel Torch Maintenance Stationbull Services Both Torch Types
bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot
Base
14Approved for Public Release Distribution is Unlimited
Metalworking processesbull PushCorp 5-HP spindle
bull AFD340 Active Compliance Device
bull BT30 Tool Changing Stationbull Grinding burring brushing
bull Miller Coolmate 3 Water Cooler
bull ATI Tool Changer
Large-scale Multi-process Robotic Gantry DED System
15Approved for Public Release Distribution is Unlimited
Monitoring Sensorsbull Synchronized weld parameter data
acquisition bull Melt Tools camera
bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal
Imaging Camerabull Non-contact measurement of surface
temperature from -4degF to 4442degFbull Inter-pass Temperature control
bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and
documentation during DED AMbull Used with both welding systems
bull Mount for Binzel Torchbull Mount for Fronius Torch
Large-scale Multi-process Robotic Gantry DED System
16Approved for Public Release Distribution is Unlimited
bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis
bull Large-scale single-sided buildsbull Large scale double-sided builds
bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing
bull DED Welding Cladding Machining
Pre-Engineered Large-scale Robotic Gantry DED Systems
17Approved for Public Release Distribution is Unlimited
bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)
bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)
bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI
bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze
bull Demonstrated single-sided integrated build platform standard qualification builds
bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems
New Capabilities - Summarybull Developed basic PowerMill Robotic DED training
seminarbull Developed advanced PowerMill robotic DED training
programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing
complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-
scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support
processes (thermal mgmt auto-maintenance quality monitoring amp control etc)
18Approved for Public Release Distribution is Unlimited
bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)
bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals
bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling
Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance
bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station
bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management
bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET
19Approved for Public Release Distribution is Unlimited
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
NSRP Robotic Arc Directed Energy Deposition (DED) Additive Manufacturing (AM) for Shipbuilding
Project TeamEWI ndash Project PINavus AutomationAustal USANSWCCDABS
Objectivesbull Convert multiple robotic weld systems to DED systemsbull Design standardized large-scale gantry DED systembull Develop digital data workflow processes bull Develop advanced training materials - workforce bull Demonstrate representative qualifications bull Provide standardized equipment amp services bull Build prototypes of increasing complexitybull Identify implementation opportunities
Reducing barriers to implement DED AM
Project Period June 2019 ndash July 2021
3Approved for Public Release Distribution is Unlimited
DED Deposition Rate vs Resolution
Courtesy Boeing
Decreased Resolution
Incr
ease
d D
epos
ition
Rat
eDEDCapability
DED AM Double-sided integrated build platform (DS-IBP) used to balance residual stresses and increase productivity
4Approved for Public Release Distribution is Unlimited
Courtesy Autodesk
Autodesk PowerMill Additive ndash DED Build Categories
5Approved for Public Release Distribution is Unlimited
bull Basic amp Adv PowerMill DED AM Launchedbull Autodesk Authorized Training Center (pending)
bull Multiple test-bed systems - training process prototypingbull IR-based preheat amp inter-pass control
bull Robot DED AM systems availablebull 7-axis Motoman Fronius Arc DED Systembull 8-axis Motoman Powder Laser DED Systembull (2) 8-axis OTC Arc DED Systemsbull Dual 8-axis Genesis Fanuc MP-Arc DED System bull 9- amp 11-axis Navus ABB MP-Arc DED Gantry
bull Additional robotic DED AM systems plannedbull 9-axis Cloos MP-Arc DED System bull 6-axis Motoman Wire Laser DED System
Robotic DED Training amp Build Test-beds
Shared EWIOSU Systems (MP) Multi-process torch changer
6Approved for Public Release Distribution is Unlimited
Robotic Arc DED SystemsMotoman - FroniusCMTGMA-PGMA
CloosMotion GMA-P amp T-GMA
Navus ABB Gantry(Multi-process DED)
OTC-Daihen GMA-PGMA
OTC-DaihenSyncroFeed
Fanuc - Lincoln GMA-PGMATW-GMA
Fanuc - Fronius amp SBI(CMTGMA-P amp Plasma)
7Approved for Public Release Distribution is Unlimited
Genesis Fanuc Robotic Arc DED Systembull Dual-arm system
bull Primary welding deposition armbull Fronius TPS 5000CMT
bull CMT GMA-P GMAbull Change waveform conditions based on build features
bull Second arm ndash flexibilitybull SBI Plasma Arc DED System (being acquired)
bull Dual-wire feedbull Auxiliary equipment scanners grinding inspection
bull Automated inter-pass temperature control bull Two axis positioner capable of building single- or
double-sided build platform structures
8Approved for Public Release Distribution is Unlimited
bull 350 Amp ACDC Invertor Systembull 290 Amp DC 100 Duty
bull Multifunctional plasma system bull Plasma joining and hardfacingbull Plasma spot weldingbull Plasma powder weldingbull Plasma brazingbull TIG welding (GTAW)bull Plasma metal deposition (directed energy
deposition) with wire and powder bull Singledual hot wire amp powder feed
SBI Plasma Arc DED
9Approved for Public Release Distribution is Unlimited
EWIOSU OTC Robotic DED SystemsSynchro-feed100 CO2No Spatter
bull Two (2) OTC 8-axis GMA-P DED Systemsbull Synchro-Feedtrade Robotic Weldingbull Welbee WB-P500L power sourcebull Inter-pass temperature control bull Two axis positioner
bull Current Ma2JIC focus bull ER5183 GMA-P DEDbull Walls amp Block Proceduresbull 6- amp 8-axis Builds
10Approved for Public Release Distribution is Unlimited
EWIOSU Cloos Robotic Multi-process DED Systembull Dual Process Test-bed
bull Motion GMA and Tandem GMAbull High melting rate T-GMA controlbull Laser depth amp IR sensorsbull 2-ton capacity double-sided builds
bull Feature - cooling rate ndash property controlbull Cryogenic cooling support processbull Maximum duty and build rate
bull Adapt waveform conditions based on build conditions to max productivity and control properties
bull Current Ma2JIC focusbull Adv High Strength Steels
11Approved for Public Release Distribution is Unlimited
Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
12Approved for Public Release Distribution is Unlimited
Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process
bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle
bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of
quality control and part certification technologies
bull Unique resource for prototyping metal DED AM structures and components
System available for large-scale DED application development
Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
13Approved for Public Release Distribution is Unlimited
Welding Processesbull Welding systems
bull Fronius TPS 500i CMT system
bull Fronius WF 60i RobactaDrive CMT Torch
bull Fronius CU 1100i Water Cooler
bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water
Coolerbull STT Power Wave module
Large-scale Multi-process Robotic Gantry DED System
bull Binzel Torch Maintenance Stationbull Services Both Torch Types
bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot
Base
14Approved for Public Release Distribution is Unlimited
Metalworking processesbull PushCorp 5-HP spindle
bull AFD340 Active Compliance Device
bull BT30 Tool Changing Stationbull Grinding burring brushing
bull Miller Coolmate 3 Water Cooler
bull ATI Tool Changer
Large-scale Multi-process Robotic Gantry DED System
15Approved for Public Release Distribution is Unlimited
Monitoring Sensorsbull Synchronized weld parameter data
acquisition bull Melt Tools camera
bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal
Imaging Camerabull Non-contact measurement of surface
temperature from -4degF to 4442degFbull Inter-pass Temperature control
bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and
documentation during DED AMbull Used with both welding systems
bull Mount for Binzel Torchbull Mount for Fronius Torch
Large-scale Multi-process Robotic Gantry DED System
16Approved for Public Release Distribution is Unlimited
bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis
bull Large-scale single-sided buildsbull Large scale double-sided builds
bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing
bull DED Welding Cladding Machining
Pre-Engineered Large-scale Robotic Gantry DED Systems
17Approved for Public Release Distribution is Unlimited
bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)
bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)
bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI
bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze
bull Demonstrated single-sided integrated build platform standard qualification builds
bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems
New Capabilities - Summarybull Developed basic PowerMill Robotic DED training
seminarbull Developed advanced PowerMill robotic DED training
programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing
complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-
scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support
processes (thermal mgmt auto-maintenance quality monitoring amp control etc)
18Approved for Public Release Distribution is Unlimited
bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)
bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals
bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling
Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance
bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station
bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management
bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET
19Approved for Public Release Distribution is Unlimited
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
DED Deposition Rate vs Resolution
Courtesy Boeing
Decreased Resolution
Incr
ease
d D
epos
ition
Rat
eDEDCapability
DED AM Double-sided integrated build platform (DS-IBP) used to balance residual stresses and increase productivity
4Approved for Public Release Distribution is Unlimited
Courtesy Autodesk
Autodesk PowerMill Additive ndash DED Build Categories
5Approved for Public Release Distribution is Unlimited
bull Basic amp Adv PowerMill DED AM Launchedbull Autodesk Authorized Training Center (pending)
bull Multiple test-bed systems - training process prototypingbull IR-based preheat amp inter-pass control
bull Robot DED AM systems availablebull 7-axis Motoman Fronius Arc DED Systembull 8-axis Motoman Powder Laser DED Systembull (2) 8-axis OTC Arc DED Systemsbull Dual 8-axis Genesis Fanuc MP-Arc DED System bull 9- amp 11-axis Navus ABB MP-Arc DED Gantry
bull Additional robotic DED AM systems plannedbull 9-axis Cloos MP-Arc DED System bull 6-axis Motoman Wire Laser DED System
Robotic DED Training amp Build Test-beds
Shared EWIOSU Systems (MP) Multi-process torch changer
6Approved for Public Release Distribution is Unlimited
Robotic Arc DED SystemsMotoman - FroniusCMTGMA-PGMA
CloosMotion GMA-P amp T-GMA
Navus ABB Gantry(Multi-process DED)
OTC-Daihen GMA-PGMA
OTC-DaihenSyncroFeed
Fanuc - Lincoln GMA-PGMATW-GMA
Fanuc - Fronius amp SBI(CMTGMA-P amp Plasma)
7Approved for Public Release Distribution is Unlimited
Genesis Fanuc Robotic Arc DED Systembull Dual-arm system
bull Primary welding deposition armbull Fronius TPS 5000CMT
bull CMT GMA-P GMAbull Change waveform conditions based on build features
bull Second arm ndash flexibilitybull SBI Plasma Arc DED System (being acquired)
bull Dual-wire feedbull Auxiliary equipment scanners grinding inspection
bull Automated inter-pass temperature control bull Two axis positioner capable of building single- or
double-sided build platform structures
8Approved for Public Release Distribution is Unlimited
bull 350 Amp ACDC Invertor Systembull 290 Amp DC 100 Duty
bull Multifunctional plasma system bull Plasma joining and hardfacingbull Plasma spot weldingbull Plasma powder weldingbull Plasma brazingbull TIG welding (GTAW)bull Plasma metal deposition (directed energy
deposition) with wire and powder bull Singledual hot wire amp powder feed
SBI Plasma Arc DED
9Approved for Public Release Distribution is Unlimited
EWIOSU OTC Robotic DED SystemsSynchro-feed100 CO2No Spatter
bull Two (2) OTC 8-axis GMA-P DED Systemsbull Synchro-Feedtrade Robotic Weldingbull Welbee WB-P500L power sourcebull Inter-pass temperature control bull Two axis positioner
bull Current Ma2JIC focus bull ER5183 GMA-P DEDbull Walls amp Block Proceduresbull 6- amp 8-axis Builds
10Approved for Public Release Distribution is Unlimited
EWIOSU Cloos Robotic Multi-process DED Systembull Dual Process Test-bed
bull Motion GMA and Tandem GMAbull High melting rate T-GMA controlbull Laser depth amp IR sensorsbull 2-ton capacity double-sided builds
bull Feature - cooling rate ndash property controlbull Cryogenic cooling support processbull Maximum duty and build rate
bull Adapt waveform conditions based on build conditions to max productivity and control properties
bull Current Ma2JIC focusbull Adv High Strength Steels
11Approved for Public Release Distribution is Unlimited
Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
12Approved for Public Release Distribution is Unlimited
Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process
bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle
bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of
quality control and part certification technologies
bull Unique resource for prototyping metal DED AM structures and components
System available for large-scale DED application development
Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
13Approved for Public Release Distribution is Unlimited
Welding Processesbull Welding systems
bull Fronius TPS 500i CMT system
bull Fronius WF 60i RobactaDrive CMT Torch
bull Fronius CU 1100i Water Cooler
bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water
Coolerbull STT Power Wave module
Large-scale Multi-process Robotic Gantry DED System
bull Binzel Torch Maintenance Stationbull Services Both Torch Types
bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot
Base
14Approved for Public Release Distribution is Unlimited
Metalworking processesbull PushCorp 5-HP spindle
bull AFD340 Active Compliance Device
bull BT30 Tool Changing Stationbull Grinding burring brushing
bull Miller Coolmate 3 Water Cooler
bull ATI Tool Changer
Large-scale Multi-process Robotic Gantry DED System
15Approved for Public Release Distribution is Unlimited
Monitoring Sensorsbull Synchronized weld parameter data
acquisition bull Melt Tools camera
bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal
Imaging Camerabull Non-contact measurement of surface
temperature from -4degF to 4442degFbull Inter-pass Temperature control
bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and
documentation during DED AMbull Used with both welding systems
bull Mount for Binzel Torchbull Mount for Fronius Torch
Large-scale Multi-process Robotic Gantry DED System
16Approved for Public Release Distribution is Unlimited
bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis
bull Large-scale single-sided buildsbull Large scale double-sided builds
bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing
bull DED Welding Cladding Machining
Pre-Engineered Large-scale Robotic Gantry DED Systems
17Approved for Public Release Distribution is Unlimited
bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)
bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)
bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI
bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze
bull Demonstrated single-sided integrated build platform standard qualification builds
bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems
New Capabilities - Summarybull Developed basic PowerMill Robotic DED training
seminarbull Developed advanced PowerMill robotic DED training
programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing
complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-
scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support
processes (thermal mgmt auto-maintenance quality monitoring amp control etc)
18Approved for Public Release Distribution is Unlimited
bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)
bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals
bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling
Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance
bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station
bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management
bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET
19Approved for Public Release Distribution is Unlimited
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
Courtesy Autodesk
Autodesk PowerMill Additive ndash DED Build Categories
5Approved for Public Release Distribution is Unlimited
bull Basic amp Adv PowerMill DED AM Launchedbull Autodesk Authorized Training Center (pending)
bull Multiple test-bed systems - training process prototypingbull IR-based preheat amp inter-pass control
bull Robot DED AM systems availablebull 7-axis Motoman Fronius Arc DED Systembull 8-axis Motoman Powder Laser DED Systembull (2) 8-axis OTC Arc DED Systemsbull Dual 8-axis Genesis Fanuc MP-Arc DED System bull 9- amp 11-axis Navus ABB MP-Arc DED Gantry
bull Additional robotic DED AM systems plannedbull 9-axis Cloos MP-Arc DED System bull 6-axis Motoman Wire Laser DED System
Robotic DED Training amp Build Test-beds
Shared EWIOSU Systems (MP) Multi-process torch changer
6Approved for Public Release Distribution is Unlimited
Robotic Arc DED SystemsMotoman - FroniusCMTGMA-PGMA
CloosMotion GMA-P amp T-GMA
Navus ABB Gantry(Multi-process DED)
OTC-Daihen GMA-PGMA
OTC-DaihenSyncroFeed
Fanuc - Lincoln GMA-PGMATW-GMA
Fanuc - Fronius amp SBI(CMTGMA-P amp Plasma)
7Approved for Public Release Distribution is Unlimited
Genesis Fanuc Robotic Arc DED Systembull Dual-arm system
bull Primary welding deposition armbull Fronius TPS 5000CMT
bull CMT GMA-P GMAbull Change waveform conditions based on build features
bull Second arm ndash flexibilitybull SBI Plasma Arc DED System (being acquired)
bull Dual-wire feedbull Auxiliary equipment scanners grinding inspection
bull Automated inter-pass temperature control bull Two axis positioner capable of building single- or
double-sided build platform structures
8Approved for Public Release Distribution is Unlimited
bull 350 Amp ACDC Invertor Systembull 290 Amp DC 100 Duty
bull Multifunctional plasma system bull Plasma joining and hardfacingbull Plasma spot weldingbull Plasma powder weldingbull Plasma brazingbull TIG welding (GTAW)bull Plasma metal deposition (directed energy
deposition) with wire and powder bull Singledual hot wire amp powder feed
SBI Plasma Arc DED
9Approved for Public Release Distribution is Unlimited
EWIOSU OTC Robotic DED SystemsSynchro-feed100 CO2No Spatter
bull Two (2) OTC 8-axis GMA-P DED Systemsbull Synchro-Feedtrade Robotic Weldingbull Welbee WB-P500L power sourcebull Inter-pass temperature control bull Two axis positioner
bull Current Ma2JIC focus bull ER5183 GMA-P DEDbull Walls amp Block Proceduresbull 6- amp 8-axis Builds
10Approved for Public Release Distribution is Unlimited
EWIOSU Cloos Robotic Multi-process DED Systembull Dual Process Test-bed
bull Motion GMA and Tandem GMAbull High melting rate T-GMA controlbull Laser depth amp IR sensorsbull 2-ton capacity double-sided builds
bull Feature - cooling rate ndash property controlbull Cryogenic cooling support processbull Maximum duty and build rate
bull Adapt waveform conditions based on build conditions to max productivity and control properties
bull Current Ma2JIC focusbull Adv High Strength Steels
11Approved for Public Release Distribution is Unlimited
Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
12Approved for Public Release Distribution is Unlimited
Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process
bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle
bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of
quality control and part certification technologies
bull Unique resource for prototyping metal DED AM structures and components
System available for large-scale DED application development
Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
13Approved for Public Release Distribution is Unlimited
Welding Processesbull Welding systems
bull Fronius TPS 500i CMT system
bull Fronius WF 60i RobactaDrive CMT Torch
bull Fronius CU 1100i Water Cooler
bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water
Coolerbull STT Power Wave module
Large-scale Multi-process Robotic Gantry DED System
bull Binzel Torch Maintenance Stationbull Services Both Torch Types
bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot
Base
14Approved for Public Release Distribution is Unlimited
Metalworking processesbull PushCorp 5-HP spindle
bull AFD340 Active Compliance Device
bull BT30 Tool Changing Stationbull Grinding burring brushing
bull Miller Coolmate 3 Water Cooler
bull ATI Tool Changer
Large-scale Multi-process Robotic Gantry DED System
15Approved for Public Release Distribution is Unlimited
Monitoring Sensorsbull Synchronized weld parameter data
acquisition bull Melt Tools camera
bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal
Imaging Camerabull Non-contact measurement of surface
temperature from -4degF to 4442degFbull Inter-pass Temperature control
bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and
documentation during DED AMbull Used with both welding systems
bull Mount for Binzel Torchbull Mount for Fronius Torch
Large-scale Multi-process Robotic Gantry DED System
16Approved for Public Release Distribution is Unlimited
bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis
bull Large-scale single-sided buildsbull Large scale double-sided builds
bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing
bull DED Welding Cladding Machining
Pre-Engineered Large-scale Robotic Gantry DED Systems
17Approved for Public Release Distribution is Unlimited
bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)
bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)
bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI
bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze
bull Demonstrated single-sided integrated build platform standard qualification builds
bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems
New Capabilities - Summarybull Developed basic PowerMill Robotic DED training
seminarbull Developed advanced PowerMill robotic DED training
programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing
complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-
scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support
processes (thermal mgmt auto-maintenance quality monitoring amp control etc)
18Approved for Public Release Distribution is Unlimited
bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)
bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals
bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling
Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance
bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station
bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management
bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET
19Approved for Public Release Distribution is Unlimited
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
bull Basic amp Adv PowerMill DED AM Launchedbull Autodesk Authorized Training Center (pending)
bull Multiple test-bed systems - training process prototypingbull IR-based preheat amp inter-pass control
bull Robot DED AM systems availablebull 7-axis Motoman Fronius Arc DED Systembull 8-axis Motoman Powder Laser DED Systembull (2) 8-axis OTC Arc DED Systemsbull Dual 8-axis Genesis Fanuc MP-Arc DED System bull 9- amp 11-axis Navus ABB MP-Arc DED Gantry
bull Additional robotic DED AM systems plannedbull 9-axis Cloos MP-Arc DED System bull 6-axis Motoman Wire Laser DED System
Robotic DED Training amp Build Test-beds
Shared EWIOSU Systems (MP) Multi-process torch changer
6Approved for Public Release Distribution is Unlimited
Robotic Arc DED SystemsMotoman - FroniusCMTGMA-PGMA
CloosMotion GMA-P amp T-GMA
Navus ABB Gantry(Multi-process DED)
OTC-Daihen GMA-PGMA
OTC-DaihenSyncroFeed
Fanuc - Lincoln GMA-PGMATW-GMA
Fanuc - Fronius amp SBI(CMTGMA-P amp Plasma)
7Approved for Public Release Distribution is Unlimited
Genesis Fanuc Robotic Arc DED Systembull Dual-arm system
bull Primary welding deposition armbull Fronius TPS 5000CMT
bull CMT GMA-P GMAbull Change waveform conditions based on build features
bull Second arm ndash flexibilitybull SBI Plasma Arc DED System (being acquired)
bull Dual-wire feedbull Auxiliary equipment scanners grinding inspection
bull Automated inter-pass temperature control bull Two axis positioner capable of building single- or
double-sided build platform structures
8Approved for Public Release Distribution is Unlimited
bull 350 Amp ACDC Invertor Systembull 290 Amp DC 100 Duty
bull Multifunctional plasma system bull Plasma joining and hardfacingbull Plasma spot weldingbull Plasma powder weldingbull Plasma brazingbull TIG welding (GTAW)bull Plasma metal deposition (directed energy
deposition) with wire and powder bull Singledual hot wire amp powder feed
SBI Plasma Arc DED
9Approved for Public Release Distribution is Unlimited
EWIOSU OTC Robotic DED SystemsSynchro-feed100 CO2No Spatter
bull Two (2) OTC 8-axis GMA-P DED Systemsbull Synchro-Feedtrade Robotic Weldingbull Welbee WB-P500L power sourcebull Inter-pass temperature control bull Two axis positioner
bull Current Ma2JIC focus bull ER5183 GMA-P DEDbull Walls amp Block Proceduresbull 6- amp 8-axis Builds
10Approved for Public Release Distribution is Unlimited
EWIOSU Cloos Robotic Multi-process DED Systembull Dual Process Test-bed
bull Motion GMA and Tandem GMAbull High melting rate T-GMA controlbull Laser depth amp IR sensorsbull 2-ton capacity double-sided builds
bull Feature - cooling rate ndash property controlbull Cryogenic cooling support processbull Maximum duty and build rate
bull Adapt waveform conditions based on build conditions to max productivity and control properties
bull Current Ma2JIC focusbull Adv High Strength Steels
11Approved for Public Release Distribution is Unlimited
Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
12Approved for Public Release Distribution is Unlimited
Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process
bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle
bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of
quality control and part certification technologies
bull Unique resource for prototyping metal DED AM structures and components
System available for large-scale DED application development
Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
13Approved for Public Release Distribution is Unlimited
Welding Processesbull Welding systems
bull Fronius TPS 500i CMT system
bull Fronius WF 60i RobactaDrive CMT Torch
bull Fronius CU 1100i Water Cooler
bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water
Coolerbull STT Power Wave module
Large-scale Multi-process Robotic Gantry DED System
bull Binzel Torch Maintenance Stationbull Services Both Torch Types
bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot
Base
14Approved for Public Release Distribution is Unlimited
Metalworking processesbull PushCorp 5-HP spindle
bull AFD340 Active Compliance Device
bull BT30 Tool Changing Stationbull Grinding burring brushing
bull Miller Coolmate 3 Water Cooler
bull ATI Tool Changer
Large-scale Multi-process Robotic Gantry DED System
15Approved for Public Release Distribution is Unlimited
Monitoring Sensorsbull Synchronized weld parameter data
acquisition bull Melt Tools camera
bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal
Imaging Camerabull Non-contact measurement of surface
temperature from -4degF to 4442degFbull Inter-pass Temperature control
bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and
documentation during DED AMbull Used with both welding systems
bull Mount for Binzel Torchbull Mount for Fronius Torch
Large-scale Multi-process Robotic Gantry DED System
16Approved for Public Release Distribution is Unlimited
bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis
bull Large-scale single-sided buildsbull Large scale double-sided builds
bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing
bull DED Welding Cladding Machining
Pre-Engineered Large-scale Robotic Gantry DED Systems
17Approved for Public Release Distribution is Unlimited
bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)
bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)
bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI
bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze
bull Demonstrated single-sided integrated build platform standard qualification builds
bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems
New Capabilities - Summarybull Developed basic PowerMill Robotic DED training
seminarbull Developed advanced PowerMill robotic DED training
programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing
complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-
scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support
processes (thermal mgmt auto-maintenance quality monitoring amp control etc)
18Approved for Public Release Distribution is Unlimited
bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)
bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals
bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling
Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance
bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station
bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management
bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET
19Approved for Public Release Distribution is Unlimited
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
Robotic Arc DED SystemsMotoman - FroniusCMTGMA-PGMA
CloosMotion GMA-P amp T-GMA
Navus ABB Gantry(Multi-process DED)
OTC-Daihen GMA-PGMA
OTC-DaihenSyncroFeed
Fanuc - Lincoln GMA-PGMATW-GMA
Fanuc - Fronius amp SBI(CMTGMA-P amp Plasma)
7Approved for Public Release Distribution is Unlimited
Genesis Fanuc Robotic Arc DED Systembull Dual-arm system
bull Primary welding deposition armbull Fronius TPS 5000CMT
bull CMT GMA-P GMAbull Change waveform conditions based on build features
bull Second arm ndash flexibilitybull SBI Plasma Arc DED System (being acquired)
bull Dual-wire feedbull Auxiliary equipment scanners grinding inspection
bull Automated inter-pass temperature control bull Two axis positioner capable of building single- or
double-sided build platform structures
8Approved for Public Release Distribution is Unlimited
bull 350 Amp ACDC Invertor Systembull 290 Amp DC 100 Duty
bull Multifunctional plasma system bull Plasma joining and hardfacingbull Plasma spot weldingbull Plasma powder weldingbull Plasma brazingbull TIG welding (GTAW)bull Plasma metal deposition (directed energy
deposition) with wire and powder bull Singledual hot wire amp powder feed
SBI Plasma Arc DED
9Approved for Public Release Distribution is Unlimited
EWIOSU OTC Robotic DED SystemsSynchro-feed100 CO2No Spatter
bull Two (2) OTC 8-axis GMA-P DED Systemsbull Synchro-Feedtrade Robotic Weldingbull Welbee WB-P500L power sourcebull Inter-pass temperature control bull Two axis positioner
bull Current Ma2JIC focus bull ER5183 GMA-P DEDbull Walls amp Block Proceduresbull 6- amp 8-axis Builds
10Approved for Public Release Distribution is Unlimited
EWIOSU Cloos Robotic Multi-process DED Systembull Dual Process Test-bed
bull Motion GMA and Tandem GMAbull High melting rate T-GMA controlbull Laser depth amp IR sensorsbull 2-ton capacity double-sided builds
bull Feature - cooling rate ndash property controlbull Cryogenic cooling support processbull Maximum duty and build rate
bull Adapt waveform conditions based on build conditions to max productivity and control properties
bull Current Ma2JIC focusbull Adv High Strength Steels
11Approved for Public Release Distribution is Unlimited
Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
12Approved for Public Release Distribution is Unlimited
Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process
bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle
bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of
quality control and part certification technologies
bull Unique resource for prototyping metal DED AM structures and components
System available for large-scale DED application development
Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
13Approved for Public Release Distribution is Unlimited
Welding Processesbull Welding systems
bull Fronius TPS 500i CMT system
bull Fronius WF 60i RobactaDrive CMT Torch
bull Fronius CU 1100i Water Cooler
bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water
Coolerbull STT Power Wave module
Large-scale Multi-process Robotic Gantry DED System
bull Binzel Torch Maintenance Stationbull Services Both Torch Types
bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot
Base
14Approved for Public Release Distribution is Unlimited
Metalworking processesbull PushCorp 5-HP spindle
bull AFD340 Active Compliance Device
bull BT30 Tool Changing Stationbull Grinding burring brushing
bull Miller Coolmate 3 Water Cooler
bull ATI Tool Changer
Large-scale Multi-process Robotic Gantry DED System
15Approved for Public Release Distribution is Unlimited
Monitoring Sensorsbull Synchronized weld parameter data
acquisition bull Melt Tools camera
bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal
Imaging Camerabull Non-contact measurement of surface
temperature from -4degF to 4442degFbull Inter-pass Temperature control
bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and
documentation during DED AMbull Used with both welding systems
bull Mount for Binzel Torchbull Mount for Fronius Torch
Large-scale Multi-process Robotic Gantry DED System
16Approved for Public Release Distribution is Unlimited
bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis
bull Large-scale single-sided buildsbull Large scale double-sided builds
bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing
bull DED Welding Cladding Machining
Pre-Engineered Large-scale Robotic Gantry DED Systems
17Approved for Public Release Distribution is Unlimited
bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)
bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)
bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI
bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze
bull Demonstrated single-sided integrated build platform standard qualification builds
bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems
New Capabilities - Summarybull Developed basic PowerMill Robotic DED training
seminarbull Developed advanced PowerMill robotic DED training
programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing
complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-
scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support
processes (thermal mgmt auto-maintenance quality monitoring amp control etc)
18Approved for Public Release Distribution is Unlimited
bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)
bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals
bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling
Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance
bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station
bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management
bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET
19Approved for Public Release Distribution is Unlimited
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
Genesis Fanuc Robotic Arc DED Systembull Dual-arm system
bull Primary welding deposition armbull Fronius TPS 5000CMT
bull CMT GMA-P GMAbull Change waveform conditions based on build features
bull Second arm ndash flexibilitybull SBI Plasma Arc DED System (being acquired)
bull Dual-wire feedbull Auxiliary equipment scanners grinding inspection
bull Automated inter-pass temperature control bull Two axis positioner capable of building single- or
double-sided build platform structures
8Approved for Public Release Distribution is Unlimited
bull 350 Amp ACDC Invertor Systembull 290 Amp DC 100 Duty
bull Multifunctional plasma system bull Plasma joining and hardfacingbull Plasma spot weldingbull Plasma powder weldingbull Plasma brazingbull TIG welding (GTAW)bull Plasma metal deposition (directed energy
deposition) with wire and powder bull Singledual hot wire amp powder feed
SBI Plasma Arc DED
9Approved for Public Release Distribution is Unlimited
EWIOSU OTC Robotic DED SystemsSynchro-feed100 CO2No Spatter
bull Two (2) OTC 8-axis GMA-P DED Systemsbull Synchro-Feedtrade Robotic Weldingbull Welbee WB-P500L power sourcebull Inter-pass temperature control bull Two axis positioner
bull Current Ma2JIC focus bull ER5183 GMA-P DEDbull Walls amp Block Proceduresbull 6- amp 8-axis Builds
10Approved for Public Release Distribution is Unlimited
EWIOSU Cloos Robotic Multi-process DED Systembull Dual Process Test-bed
bull Motion GMA and Tandem GMAbull High melting rate T-GMA controlbull Laser depth amp IR sensorsbull 2-ton capacity double-sided builds
bull Feature - cooling rate ndash property controlbull Cryogenic cooling support processbull Maximum duty and build rate
bull Adapt waveform conditions based on build conditions to max productivity and control properties
bull Current Ma2JIC focusbull Adv High Strength Steels
11Approved for Public Release Distribution is Unlimited
Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
12Approved for Public Release Distribution is Unlimited
Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process
bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle
bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of
quality control and part certification technologies
bull Unique resource for prototyping metal DED AM structures and components
System available for large-scale DED application development
Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
13Approved for Public Release Distribution is Unlimited
Welding Processesbull Welding systems
bull Fronius TPS 500i CMT system
bull Fronius WF 60i RobactaDrive CMT Torch
bull Fronius CU 1100i Water Cooler
bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water
Coolerbull STT Power Wave module
Large-scale Multi-process Robotic Gantry DED System
bull Binzel Torch Maintenance Stationbull Services Both Torch Types
bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot
Base
14Approved for Public Release Distribution is Unlimited
Metalworking processesbull PushCorp 5-HP spindle
bull AFD340 Active Compliance Device
bull BT30 Tool Changing Stationbull Grinding burring brushing
bull Miller Coolmate 3 Water Cooler
bull ATI Tool Changer
Large-scale Multi-process Robotic Gantry DED System
15Approved for Public Release Distribution is Unlimited
Monitoring Sensorsbull Synchronized weld parameter data
acquisition bull Melt Tools camera
bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal
Imaging Camerabull Non-contact measurement of surface
temperature from -4degF to 4442degFbull Inter-pass Temperature control
bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and
documentation during DED AMbull Used with both welding systems
bull Mount for Binzel Torchbull Mount for Fronius Torch
Large-scale Multi-process Robotic Gantry DED System
16Approved for Public Release Distribution is Unlimited
bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis
bull Large-scale single-sided buildsbull Large scale double-sided builds
bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing
bull DED Welding Cladding Machining
Pre-Engineered Large-scale Robotic Gantry DED Systems
17Approved for Public Release Distribution is Unlimited
bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)
bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)
bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI
bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze
bull Demonstrated single-sided integrated build platform standard qualification builds
bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems
New Capabilities - Summarybull Developed basic PowerMill Robotic DED training
seminarbull Developed advanced PowerMill robotic DED training
programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing
complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-
scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support
processes (thermal mgmt auto-maintenance quality monitoring amp control etc)
18Approved for Public Release Distribution is Unlimited
bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)
bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals
bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling
Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance
bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station
bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management
bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET
19Approved for Public Release Distribution is Unlimited
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
bull 350 Amp ACDC Invertor Systembull 290 Amp DC 100 Duty
bull Multifunctional plasma system bull Plasma joining and hardfacingbull Plasma spot weldingbull Plasma powder weldingbull Plasma brazingbull TIG welding (GTAW)bull Plasma metal deposition (directed energy
deposition) with wire and powder bull Singledual hot wire amp powder feed
SBI Plasma Arc DED
9Approved for Public Release Distribution is Unlimited
EWIOSU OTC Robotic DED SystemsSynchro-feed100 CO2No Spatter
bull Two (2) OTC 8-axis GMA-P DED Systemsbull Synchro-Feedtrade Robotic Weldingbull Welbee WB-P500L power sourcebull Inter-pass temperature control bull Two axis positioner
bull Current Ma2JIC focus bull ER5183 GMA-P DEDbull Walls amp Block Proceduresbull 6- amp 8-axis Builds
10Approved for Public Release Distribution is Unlimited
EWIOSU Cloos Robotic Multi-process DED Systembull Dual Process Test-bed
bull Motion GMA and Tandem GMAbull High melting rate T-GMA controlbull Laser depth amp IR sensorsbull 2-ton capacity double-sided builds
bull Feature - cooling rate ndash property controlbull Cryogenic cooling support processbull Maximum duty and build rate
bull Adapt waveform conditions based on build conditions to max productivity and control properties
bull Current Ma2JIC focusbull Adv High Strength Steels
11Approved for Public Release Distribution is Unlimited
Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
12Approved for Public Release Distribution is Unlimited
Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process
bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle
bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of
quality control and part certification technologies
bull Unique resource for prototyping metal DED AM structures and components
System available for large-scale DED application development
Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
13Approved for Public Release Distribution is Unlimited
Welding Processesbull Welding systems
bull Fronius TPS 500i CMT system
bull Fronius WF 60i RobactaDrive CMT Torch
bull Fronius CU 1100i Water Cooler
bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water
Coolerbull STT Power Wave module
Large-scale Multi-process Robotic Gantry DED System
bull Binzel Torch Maintenance Stationbull Services Both Torch Types
bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot
Base
14Approved for Public Release Distribution is Unlimited
Metalworking processesbull PushCorp 5-HP spindle
bull AFD340 Active Compliance Device
bull BT30 Tool Changing Stationbull Grinding burring brushing
bull Miller Coolmate 3 Water Cooler
bull ATI Tool Changer
Large-scale Multi-process Robotic Gantry DED System
15Approved for Public Release Distribution is Unlimited
Monitoring Sensorsbull Synchronized weld parameter data
acquisition bull Melt Tools camera
bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal
Imaging Camerabull Non-contact measurement of surface
temperature from -4degF to 4442degFbull Inter-pass Temperature control
bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and
documentation during DED AMbull Used with both welding systems
bull Mount for Binzel Torchbull Mount for Fronius Torch
Large-scale Multi-process Robotic Gantry DED System
16Approved for Public Release Distribution is Unlimited
bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis
bull Large-scale single-sided buildsbull Large scale double-sided builds
bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing
bull DED Welding Cladding Machining
Pre-Engineered Large-scale Robotic Gantry DED Systems
17Approved for Public Release Distribution is Unlimited
bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)
bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)
bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI
bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze
bull Demonstrated single-sided integrated build platform standard qualification builds
bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems
New Capabilities - Summarybull Developed basic PowerMill Robotic DED training
seminarbull Developed advanced PowerMill robotic DED training
programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing
complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-
scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support
processes (thermal mgmt auto-maintenance quality monitoring amp control etc)
18Approved for Public Release Distribution is Unlimited
bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)
bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals
bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling
Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance
bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station
bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management
bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET
19Approved for Public Release Distribution is Unlimited
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
EWIOSU OTC Robotic DED SystemsSynchro-feed100 CO2No Spatter
bull Two (2) OTC 8-axis GMA-P DED Systemsbull Synchro-Feedtrade Robotic Weldingbull Welbee WB-P500L power sourcebull Inter-pass temperature control bull Two axis positioner
bull Current Ma2JIC focus bull ER5183 GMA-P DEDbull Walls amp Block Proceduresbull 6- amp 8-axis Builds
10Approved for Public Release Distribution is Unlimited
EWIOSU Cloos Robotic Multi-process DED Systembull Dual Process Test-bed
bull Motion GMA and Tandem GMAbull High melting rate T-GMA controlbull Laser depth amp IR sensorsbull 2-ton capacity double-sided builds
bull Feature - cooling rate ndash property controlbull Cryogenic cooling support processbull Maximum duty and build rate
bull Adapt waveform conditions based on build conditions to max productivity and control properties
bull Current Ma2JIC focusbull Adv High Strength Steels
11Approved for Public Release Distribution is Unlimited
Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
12Approved for Public Release Distribution is Unlimited
Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process
bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle
bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of
quality control and part certification technologies
bull Unique resource for prototyping metal DED AM structures and components
System available for large-scale DED application development
Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
13Approved for Public Release Distribution is Unlimited
Welding Processesbull Welding systems
bull Fronius TPS 500i CMT system
bull Fronius WF 60i RobactaDrive CMT Torch
bull Fronius CU 1100i Water Cooler
bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water
Coolerbull STT Power Wave module
Large-scale Multi-process Robotic Gantry DED System
bull Binzel Torch Maintenance Stationbull Services Both Torch Types
bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot
Base
14Approved for Public Release Distribution is Unlimited
Metalworking processesbull PushCorp 5-HP spindle
bull AFD340 Active Compliance Device
bull BT30 Tool Changing Stationbull Grinding burring brushing
bull Miller Coolmate 3 Water Cooler
bull ATI Tool Changer
Large-scale Multi-process Robotic Gantry DED System
15Approved for Public Release Distribution is Unlimited
Monitoring Sensorsbull Synchronized weld parameter data
acquisition bull Melt Tools camera
bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal
Imaging Camerabull Non-contact measurement of surface
temperature from -4degF to 4442degFbull Inter-pass Temperature control
bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and
documentation during DED AMbull Used with both welding systems
bull Mount for Binzel Torchbull Mount for Fronius Torch
Large-scale Multi-process Robotic Gantry DED System
16Approved for Public Release Distribution is Unlimited
bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis
bull Large-scale single-sided buildsbull Large scale double-sided builds
bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing
bull DED Welding Cladding Machining
Pre-Engineered Large-scale Robotic Gantry DED Systems
17Approved for Public Release Distribution is Unlimited
bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)
bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)
bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI
bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze
bull Demonstrated single-sided integrated build platform standard qualification builds
bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems
New Capabilities - Summarybull Developed basic PowerMill Robotic DED training
seminarbull Developed advanced PowerMill robotic DED training
programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing
complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-
scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support
processes (thermal mgmt auto-maintenance quality monitoring amp control etc)
18Approved for Public Release Distribution is Unlimited
bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)
bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals
bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling
Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance
bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station
bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management
bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET
19Approved for Public Release Distribution is Unlimited
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
EWIOSU Cloos Robotic Multi-process DED Systembull Dual Process Test-bed
bull Motion GMA and Tandem GMAbull High melting rate T-GMA controlbull Laser depth amp IR sensorsbull 2-ton capacity double-sided builds
bull Feature - cooling rate ndash property controlbull Cryogenic cooling support processbull Maximum duty and build rate
bull Adapt waveform conditions based on build conditions to max productivity and control properties
bull Current Ma2JIC focusbull Adv High Strength Steels
11Approved for Public Release Distribution is Unlimited
Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
12Approved for Public Release Distribution is Unlimited
Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process
bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle
bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of
quality control and part certification technologies
bull Unique resource for prototyping metal DED AM structures and components
System available for large-scale DED application development
Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
13Approved for Public Release Distribution is Unlimited
Welding Processesbull Welding systems
bull Fronius TPS 500i CMT system
bull Fronius WF 60i RobactaDrive CMT Torch
bull Fronius CU 1100i Water Cooler
bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water
Coolerbull STT Power Wave module
Large-scale Multi-process Robotic Gantry DED System
bull Binzel Torch Maintenance Stationbull Services Both Torch Types
bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot
Base
14Approved for Public Release Distribution is Unlimited
Metalworking processesbull PushCorp 5-HP spindle
bull AFD340 Active Compliance Device
bull BT30 Tool Changing Stationbull Grinding burring brushing
bull Miller Coolmate 3 Water Cooler
bull ATI Tool Changer
Large-scale Multi-process Robotic Gantry DED System
15Approved for Public Release Distribution is Unlimited
Monitoring Sensorsbull Synchronized weld parameter data
acquisition bull Melt Tools camera
bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal
Imaging Camerabull Non-contact measurement of surface
temperature from -4degF to 4442degFbull Inter-pass Temperature control
bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and
documentation during DED AMbull Used with both welding systems
bull Mount for Binzel Torchbull Mount for Fronius Torch
Large-scale Multi-process Robotic Gantry DED System
16Approved for Public Release Distribution is Unlimited
bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis
bull Large-scale single-sided buildsbull Large scale double-sided builds
bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing
bull DED Welding Cladding Machining
Pre-Engineered Large-scale Robotic Gantry DED Systems
17Approved for Public Release Distribution is Unlimited
bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)
bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)
bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI
bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze
bull Demonstrated single-sided integrated build platform standard qualification builds
bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems
New Capabilities - Summarybull Developed basic PowerMill Robotic DED training
seminarbull Developed advanced PowerMill robotic DED training
programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing
complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-
scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support
processes (thermal mgmt auto-maintenance quality monitoring amp control etc)
18Approved for Public Release Distribution is Unlimited
bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)
bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals
bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling
Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance
bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station
bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management
bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET
19Approved for Public Release Distribution is Unlimited
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
Air Products In-situ Liquid Nitrogen Cryogenic Cooling (ILNCC)
12Approved for Public Release Distribution is Unlimited
Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process
bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle
bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of
quality control and part certification technologies
bull Unique resource for prototyping metal DED AM structures and components
System available for large-scale DED application development
Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
13Approved for Public Release Distribution is Unlimited
Welding Processesbull Welding systems
bull Fronius TPS 500i CMT system
bull Fronius WF 60i RobactaDrive CMT Torch
bull Fronius CU 1100i Water Cooler
bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water
Coolerbull STT Power Wave module
Large-scale Multi-process Robotic Gantry DED System
bull Binzel Torch Maintenance Stationbull Services Both Torch Types
bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot
Base
14Approved for Public Release Distribution is Unlimited
Metalworking processesbull PushCorp 5-HP spindle
bull AFD340 Active Compliance Device
bull BT30 Tool Changing Stationbull Grinding burring brushing
bull Miller Coolmate 3 Water Cooler
bull ATI Tool Changer
Large-scale Multi-process Robotic Gantry DED System
15Approved for Public Release Distribution is Unlimited
Monitoring Sensorsbull Synchronized weld parameter data
acquisition bull Melt Tools camera
bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal
Imaging Camerabull Non-contact measurement of surface
temperature from -4degF to 4442degFbull Inter-pass Temperature control
bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and
documentation during DED AMbull Used with both welding systems
bull Mount for Binzel Torchbull Mount for Fronius Torch
Large-scale Multi-process Robotic Gantry DED System
16Approved for Public Release Distribution is Unlimited
bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis
bull Large-scale single-sided buildsbull Large scale double-sided builds
bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing
bull DED Welding Cladding Machining
Pre-Engineered Large-scale Robotic Gantry DED Systems
17Approved for Public Release Distribution is Unlimited
bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)
bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)
bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI
bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze
bull Demonstrated single-sided integrated build platform standard qualification builds
bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems
New Capabilities - Summarybull Developed basic PowerMill Robotic DED training
seminarbull Developed advanced PowerMill robotic DED training
programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing
complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-
scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support
processes (thermal mgmt auto-maintenance quality monitoring amp control etc)
18Approved for Public Release Distribution is Unlimited
bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)
bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals
bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling
Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance
bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station
bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management
bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET
19Approved for Public Release Distribution is Unlimited
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
Pre-engineered (COTS) Systembull 8-10-ft high x 14-ft wide x 30-ft longbull 60 Kg ABB IRB 4600 Robotbull Multi-process
bull Fronius CMT Lincoln Power Wavebull Arc Laser Hybrid laser-arcbull PushCorp Grinderbrusherburring spindle
bull 11-axis w 1-ton tiltturn positioner bull Sensor platform for development of
quality control and part certification technologies
bull Unique resource for prototyping metal DED AM structures and components
System available for large-scale DED application development
Large-scale Multi-process Robotic Gantry DEDSystem ndash Commission July 2020
13Approved for Public Release Distribution is Unlimited
Welding Processesbull Welding systems
bull Fronius TPS 500i CMT system
bull Fronius WF 60i RobactaDrive CMT Torch
bull Fronius CU 1100i Water Cooler
bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water
Coolerbull STT Power Wave module
Large-scale Multi-process Robotic Gantry DED System
bull Binzel Torch Maintenance Stationbull Services Both Torch Types
bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot
Base
14Approved for Public Release Distribution is Unlimited
Metalworking processesbull PushCorp 5-HP spindle
bull AFD340 Active Compliance Device
bull BT30 Tool Changing Stationbull Grinding burring brushing
bull Miller Coolmate 3 Water Cooler
bull ATI Tool Changer
Large-scale Multi-process Robotic Gantry DED System
15Approved for Public Release Distribution is Unlimited
Monitoring Sensorsbull Synchronized weld parameter data
acquisition bull Melt Tools camera
bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal
Imaging Camerabull Non-contact measurement of surface
temperature from -4degF to 4442degFbull Inter-pass Temperature control
bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and
documentation during DED AMbull Used with both welding systems
bull Mount for Binzel Torchbull Mount for Fronius Torch
Large-scale Multi-process Robotic Gantry DED System
16Approved for Public Release Distribution is Unlimited
bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis
bull Large-scale single-sided buildsbull Large scale double-sided builds
bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing
bull DED Welding Cladding Machining
Pre-Engineered Large-scale Robotic Gantry DED Systems
17Approved for Public Release Distribution is Unlimited
bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)
bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)
bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI
bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze
bull Demonstrated single-sided integrated build platform standard qualification builds
bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems
New Capabilities - Summarybull Developed basic PowerMill Robotic DED training
seminarbull Developed advanced PowerMill robotic DED training
programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing
complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-
scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support
processes (thermal mgmt auto-maintenance quality monitoring amp control etc)
18Approved for Public Release Distribution is Unlimited
bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)
bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals
bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling
Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance
bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station
bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management
bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET
19Approved for Public Release Distribution is Unlimited
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
Welding Processesbull Welding systems
bull Fronius TPS 500i CMT system
bull Fronius WF 60i RobactaDrive CMT Torch
bull Fronius CU 1100i Water Cooler
bull Lincoln S500 systembull Binzel ROBOWH-WC Torchbull Lincoln Cool Arc 55 S Water
Coolerbull STT Power Wave module
Large-scale Multi-process Robotic Gantry DED System
bull Binzel Torch Maintenance Stationbull Services Both Torch Types
bull Binzel Torch Exchange Stationsbull ABB Bullseye bull Additional Wire Clipper at Robot
Base
14Approved for Public Release Distribution is Unlimited
Metalworking processesbull PushCorp 5-HP spindle
bull AFD340 Active Compliance Device
bull BT30 Tool Changing Stationbull Grinding burring brushing
bull Miller Coolmate 3 Water Cooler
bull ATI Tool Changer
Large-scale Multi-process Robotic Gantry DED System
15Approved for Public Release Distribution is Unlimited
Monitoring Sensorsbull Synchronized weld parameter data
acquisition bull Melt Tools camera
bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal
Imaging Camerabull Non-contact measurement of surface
temperature from -4degF to 4442degFbull Inter-pass Temperature control
bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and
documentation during DED AMbull Used with both welding systems
bull Mount for Binzel Torchbull Mount for Fronius Torch
Large-scale Multi-process Robotic Gantry DED System
16Approved for Public Release Distribution is Unlimited
bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis
bull Large-scale single-sided buildsbull Large scale double-sided builds
bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing
bull DED Welding Cladding Machining
Pre-Engineered Large-scale Robotic Gantry DED Systems
17Approved for Public Release Distribution is Unlimited
bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)
bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)
bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI
bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze
bull Demonstrated single-sided integrated build platform standard qualification builds
bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems
New Capabilities - Summarybull Developed basic PowerMill Robotic DED training
seminarbull Developed advanced PowerMill robotic DED training
programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing
complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-
scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support
processes (thermal mgmt auto-maintenance quality monitoring amp control etc)
18Approved for Public Release Distribution is Unlimited
bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)
bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals
bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling
Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance
bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station
bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management
bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET
19Approved for Public Release Distribution is Unlimited
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
Metalworking processesbull PushCorp 5-HP spindle
bull AFD340 Active Compliance Device
bull BT30 Tool Changing Stationbull Grinding burring brushing
bull Miller Coolmate 3 Water Cooler
bull ATI Tool Changer
Large-scale Multi-process Robotic Gantry DED System
15Approved for Public Release Distribution is Unlimited
Monitoring Sensorsbull Synchronized weld parameter data
acquisition bull Melt Tools camera
bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal
Imaging Camerabull Non-contact measurement of surface
temperature from -4degF to 4442degFbull Inter-pass Temperature control
bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and
documentation during DED AMbull Used with both welding systems
bull Mount for Binzel Torchbull Mount for Fronius Torch
Large-scale Multi-process Robotic Gantry DED System
16Approved for Public Release Distribution is Unlimited
bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis
bull Large-scale single-sided buildsbull Large scale double-sided builds
bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing
bull DED Welding Cladding Machining
Pre-Engineered Large-scale Robotic Gantry DED Systems
17Approved for Public Release Distribution is Unlimited
bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)
bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)
bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI
bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze
bull Demonstrated single-sided integrated build platform standard qualification builds
bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems
New Capabilities - Summarybull Developed basic PowerMill Robotic DED training
seminarbull Developed advanced PowerMill robotic DED training
programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing
complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-
scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support
processes (thermal mgmt auto-maintenance quality monitoring amp control etc)
18Approved for Public Release Distribution is Unlimited
bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)
bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals
bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling
Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance
bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station
bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management
bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET
19Approved for Public Release Distribution is Unlimited
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
Monitoring Sensorsbull Synchronized weld parameter data
acquisition bull Melt Tools camera
bull Weld pool monitoringbull Micro-Epsilon TIM 640 Thermal
Imaging Camerabull Non-contact measurement of surface
temperature from -4degF to 4442degFbull Inter-pass Temperature control
bull Binzel TH6D-GF Sensorbull Seam tracking and finding bull Profile measurement and
documentation during DED AMbull Used with both welding systems
bull Mount for Binzel Torchbull Mount for Fronius Torch
Large-scale Multi-process Robotic Gantry DED System
16Approved for Public Release Distribution is Unlimited
bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis
bull Large-scale single-sided buildsbull Large scale double-sided builds
bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing
bull DED Welding Cladding Machining
Pre-Engineered Large-scale Robotic Gantry DED Systems
17Approved for Public Release Distribution is Unlimited
bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)
bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)
bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI
bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze
bull Demonstrated single-sided integrated build platform standard qualification builds
bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems
New Capabilities - Summarybull Developed basic PowerMill Robotic DED training
seminarbull Developed advanced PowerMill robotic DED training
programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing
complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-
scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support
processes (thermal mgmt auto-maintenance quality monitoring amp control etc)
18Approved for Public Release Distribution is Unlimited
bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)
bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals
bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling
Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance
bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station
bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management
bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET
19Approved for Public Release Distribution is Unlimited
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
bull Digital-twin available for build simulationsbull Post-processors solved for 9- amp 11- axis
bull Large-scale single-sided buildsbull Large scale double-sided builds
bull System Derivatives bull Largesmaller work envelopebull Head stocktail stock ndash double-sided buildsbull High deposition arc DED packagesbull Laser DED packagesbull Digital manufacturing
bull DED Welding Cladding Machining
Pre-Engineered Large-scale Robotic Gantry DED Systems
17Approved for Public Release Distribution is Unlimited
bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)
bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)
bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI
bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze
bull Demonstrated single-sided integrated build platform standard qualification builds
bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems
New Capabilities - Summarybull Developed basic PowerMill Robotic DED training
seminarbull Developed advanced PowerMill robotic DED training
programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing
complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-
scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support
processes (thermal mgmt auto-maintenance quality monitoring amp control etc)
18Approved for Public Release Distribution is Unlimited
bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)
bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals
bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling
Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance
bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station
bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management
bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET
19Approved for Public Release Distribution is Unlimited
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
bull Established digital twin and post-processor for 7 robotic DED systems (1-Motoman 3-Fanuc 2-OTC 1 ABB)
bull Developed integrated and installed large-scale robotic DED Test-bed (supplied by NavusABB)
bull Developed 9- and 11-axis digital twin model amp post-processor for large-scale robotic gantry DED system installed at EWI
bull Developed DED procedure models for 308L stainless steel and nickel aluminum bronze
bull Demonstrated single-sided integrated build platform standard qualification builds
bull Built basic components of increasing complexity (coupler propeller blade) with platform robotic DED systems
New Capabilities - Summarybull Developed basic PowerMill Robotic DED training
seminarbull Developed advanced PowerMill robotic DED training
programbull Launching Autodesk Authorized Training Center (ATC)bull Building basic amp advanced components of increasing
complexity with gantry test-bedbull Offering (Navus) pre-engineeredstandardized large-
scale DED system(s) for industry acquisitionbull Planning development of ldquoLights-outrdquo support
processes (thermal mgmt auto-maintenance quality monitoring amp control etc)
18Approved for Public Release Distribution is Unlimited
bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)
bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals
bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling
Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance
bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station
bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management
bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET
19Approved for Public Release Distribution is Unlimited
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
bull Thermal management systembull Infrared camerabull PreheatInter-pass control bull Forced cooling system and methodsbull Cooling rate control (long range)
bull Hybrid ManufacturingIn-situ Clean Machiningbull 3-axis gantry milling for hard metals
bull Z-axis upgrade conceptbull Robotic grinding for hard metalbull Robotic routing for soft metalsbull Startstop contour grindingbull Incremental feature grindingmillingbull Clean Machining with In-situ Clean Cryogenic Cooling
Ongoing Development Needs - Lights-out Technologybull Automated torch maintenance
bull Torch cleanersbull Wire cutterbull Necktip changerbull Cloos Sparematic auto nozzle and tip changer bull Binzel neck changer station
bull Process quality monitoringbull Process behavior amp parameter analysisbull Pool behavior bull Feature - cooling rate ndash property modelingbull Dimensional data amp management
bull In-situ NDEbull PowerInspect Software Suitebull Vision processingbull UT ET AET
19Approved for Public Release Distribution is Unlimited
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
bull Develop advanced large-scale builds and prototypes for candidate shipyard applications
bull Develop DED models for different materials and featuresbull Demonstrate qualification builds and feature prototypes
bull Evaluate alternative DED processes (plasma arc wire arc)bull Develop Part (Component) Verification Scheme Requirements
bull Technical Publication - NAVSEA Process Requirements for Metal Directed Energy Deposition
bull Develop DED AM operations and process prototypes forbull Part Verification Build Procedure(s) Workflowbull Quality Assurance Systembull Process Control Planbull Training Plan
Ongoing Development Needs
Accelerate shipyard implementationand impact
20Approved for Public Release Distribution is Unlimited
Questions
21
Questions
21