10 September 2014
Additive Manufacturing
James Sears
Additive Manufacturing Lab GE Global Research , Niskayuna, NY
GE Internal
2 September 18, 2014
GE-GR: Market Focused R&D
• First U.S. industrial lab
• Began 1900 in Schenectady, NY
• Today: 3000 technologists, 6+ sites
• Founding principle … improve businesses through technology
Cornerstone of GE’s commitment to technology
GE Internal
3 September 18, 2014
GE-GR: Manufacturing Research Efforts Advanced Machining Electro-Machining Shaped-Hole Drilling Superfinishing Processes “Intelligent” Machining
Composites Ceramic Matrix Composites Polymer Matrix Composites Automated Fiber Placement Inline Inspection & Monitoring
Metal Processing Centrifugal Casting Directional Solidification Powder Metallurgy Forging Processes
Coatings Low-Cost TBC’s Suspension Plasma Spray Thin Films for Solar Ice-Phobic Nano Coatings
Operations Research Factory Simulation & Optimization RFID Tracking Data Telecommunications Mfg Data Informatics
Manufacturing Scale Up Mfg Readiness Level Assessment Equipment Design Pilot Scale Production Low Rate initial Production
Services Repair Applications On-Site Field Services In-Situ Inspection & Repair Automated Workscoping
Additive Manufacturing Design for Additive Tools Metal & Ceramic Processes Polymer Rapid Prototyping Micro-scale deposition
Laser Processes Thick-Section Welding Laser Surface Treatments Laser fundamentals Process Controls
Inspection 3D Boroscope Inspections Optical Metrology Inline CT Automated Defect Recognition
4
Additive Manufacturing (AM)
https://www.youtube.com/watch?v=GjbkxVku39Y
Metals (High-Temperature Alloys) Ceramics Polymers
5
Conventional Manufacturing vs AM
Start with a pre-formed billet , which gets formed and machined.
Material properties unchanged and cannot be location specific
Limited to known set of geometries
Design constrained by manufacturing
Requires extensive tooling
Conventional Additive
Start with a powder or wire and produce part layer upon layer upon layer.
Build material properties as part is built … location specific
More complex geometries possible
Allows for faster iterations between design, materials and manufacturing
Minimal tooling required
Material properties created during manufacturing Ability to tailor by location
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AM: No Constraints on Design
One piece stapler
Structural elements + Heat exchanger
PROTOTYPING: BIGGEST APPLICATION FOR AM BMW APPLICATIONS: ACCELERATE THE DESIGN CYCLE
Vehicle front using SLS
Various motor parts using SLS
Crankshaft using SLA
Rear motorcycle wheel using SLA
15-20K parts/year all consumed during testing
PROTOTYPING: ELECTRONICS & FLUIDICS BMW APPLICATIONS: ACCELERATE THE DESIGN CYCLE
Courtesy of Harvard University & UTEP
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Customized One-of-Parts + Specialty Materials − Aerospace: design visualization, testing
− Healthcare: Surgical aids, dental, prostheses
− Product design: touch-feel prototypes
Healthcare
Visualization & surgical aids (full 3D color printing)
Implants – 3D printed jaw & hip joints
Custom dentures – 50K parts/day
Align Technologies, CA
CT collimators – Dunlee (Philips)
Move towards the industrial use of AM Public
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AM: Market Overview & Trends •Total market size: 1.714B (services & products worldwide)
•AM market growth in 2011: 29.4%
Services growth Product growth
Year Overall growth%
Product growth %
Service growth %
2008 3.7% 0.0% 7.9%
2009 -9.8% -13.2% -6.2%
2010 24.1% 22.9% 25.3%
2011 29.4% 28.0% 30.7%
Secondary market*( enabled by AM: $1.08B Total AM revenue: $2.79B in 2011
*Tooling, molding, castings processes etc derived from AM
Primary market:
Public
11 GE Title or job number
9/18/2014
Overview of Presentation
• Where is AM being used
• Potential areas of collaboration in AM technology development
Micro-additive AM
Direct-written sensors
Metals additive manufacturing
• Future perspective
Additive Manufacturing @ GE Two primary uses:
• Rapid prototyping to compress the design cycle
• Manufacturing of previously “difficult-to“ manufacture high-performance components at cost
“We are standing in front of a potential revolution in manufacturing”, Michael Idelchik, VP of Advanced Technologies, GE Global Research as quoted in the
Economist , April, 2012
Design
Manufacturing
Materials
GE Internal
AM Technologies at GE
Resolution 15 µm 200 µm 500 µm
Large-scale features
• Turbomachinery applications • Test hardware • Limited production begins 2013
• Metal leading edge • GEA Repair & feature addition • In use
U/S probes Functional metal, ceramics & polymer parts
Commercial polymer & metal machines
Large one-off functional metal parts
Custom built machines
Macro-scale features Micro-scale features
• Ultrasound probes • Direct-written CBM sensors • Pilot production 2013
• Direct ceramic deposition
• Direct written sensors
• DMLM & Electron beam
• Commercial polymer AM • Spray technologies
• Laser & EB cladding
CBM Sensors
Ceramics printing
Direct write
Public
GE Internal
Micro-AM: Digital Micro-Printing • Low cost, highly adaptive meso-scale manufacturing method - 15-20 micron feature size in X-Y
• Large area patterning – currently X-Y-Z - 6”x6”x2”, scalable to larger areas
• Layered deposition of photopolymer slurry loaded with ceramic/metal particles
• Photocuring with digital masks – wide range of 3D geometries
Public
GE Internal
Micro-AM: Digital Micro-Printing (DMP)
• High aspect ratio structures, shapes on demand
• Materials demonstrated: Alumina, Piezoceramics (PZT), Platinum, Phosphors
50 mm layers, 500 mm tall – Polymer
(Photocurable Acrylate)
50 mm layers, sintered, Alumina
15 micron posts, polymer
(Photocurable Acrylate)
Pt
PZT
Pt-PZT co-deposited & co-
sintered
Periodic piezoceramic columnar array
~80 micron columns
Aperiodic piezoceramic columns
40-80 micron columns
100 microns
GE Internal
DMP: Ultrasound Transducers
Piezoelectric transducer elements
Conventional Process: Dicing
(Slow, expensive, resolution/geometry limited)
Disruptive: DMP
(Faster, higher resolution, unique sensor architectures)
Ultrasound Transducer
Un-dicable geometries: staggered columns High Frequency (15-25 MHz) ultrasound probes:
100 microns
Custom design of
transducers
GE Internal
Est Vol%: 0.3
fp (MHz) fs (MHz) kt Qm h33 (V/m) KS
3 KT
3Tan K
S3 K
T3
101709-101709-02_P1 17.4 14.8 0.571 6.03 2148 304 550 -0.023 1013 1833
101709-101709-02_P2 17.6 14.9 0.575 6.05 2145 315 576 -0.023 1050 1919
101709-101709-02_P3 17.3 14.7 0.567 5.36 2098 311 566 -0.027 1037 1885
101709-101709-02_P4 17.3 14.6 0.574 5.37 2086 319 591 -0.026 1063 1970
101809-101709-02_P1 16.9 14.7 0.543 5.20 1805 390 680 -0.022 1299 2268
101809-101709-02_P2 16.5 14.4 0.535 5.30 1813 355 613 -0.023 1182 2045
101809-101709-02_P3 16.3 14.1 0.536 5.48 1826 343 586 -0.022 1144 1955
101809-101709-02_P4 16.5 14.4 0.529 4.96 1775 361 624 -0.024 1202 2080
101909-101909-02_P1 27.8 24.1 0.538 6.05 1687 404 700 -0.028 1346 2334
101909-101909-02_P2 28.1 24.4 0.535 6.30 1665 417 727 -0.030 1389 2423
101909-101909-02_P3 28.0 24.4 0.530 6.18 1687 396 686 -0.028 1318 2285
101909-101909-02_P4 28.2 24.4 0.538 5.98 1770 375 658 -0.030 1251 2194
Comp Ceramic
Conventional Vs. Digital Micro-Printing
Cleaner impedance plots – via optimization of the
transducer structure
Conventional Optimized (DMP)
Modes eliminated Spurious modes
GE Internal
DMP: Printed Materal/Fetal U/S Probes
Resolution Phantom Fetal Phantom
•Jointly funded by the National Institute of Health and GE-MCS
•Lab demo of printed 4C probes (maternal/fetal); sensitivity debit noted
In-house AM system developed Results
Coupling coefficient (kt): 0.53
This project is supported in part by Award Number 1RC2EB011439 from the National Institute of Biomedical Imaging and Bioengineering (NIBIB). The
content is solely the responsibility of the authors and does not necessarily represent the official views of NIBIB or the NIH.
GE Internal
Direct-Write Sensors and Structures
Direct Write Nozzles (nScrypt Inc.) – DARPA MICE Sample YSZ & YSZ:Eu deposition
• Directly write an ink with a high loading of ceramic or metal on 3D substrate
• Feature resolution ~50 microns w/t particle inks, ~10 microns w/t sol gels
• GRC efforts: adapt nozzles to GE materials, e.g. custom inks
Applications: • Temperature/strain sensors, condition monitoring, bio-material traces
Development requirements: • Materials: Inks with high loading, finer particle sizes, sol-gels
• Structures: Higher resolution, multi-material structures
GE Internal
Micro-Scale AM: Other Applications
Other material systems:
- Magnetics
- Optical structures
- Thermo-electrics
- Bio-materials ?
- Others ..
- Graded materials ?
Macro-Scale AM
Macro-Scale: Polymer Processes
Fused deposition modeling - Filament extrusion - Thermoplastics: ABS, polycarbonates - Companies: Stratasys, Makerbot
Stereolithography - Selective photo-polymerization - Thermosets: acrylates epoxies - Companies: 3D Systems, Envisiontec
Multi-jet printing - Direct material or binder dep. via inkjet - Acrylates, plaster-of-paris, ceramics - Companies: 3D Systems, Stratasys, Voxeljet
Selective laser sintering - Direct sintering of powder in a bed - Thermoplastics - Companies: EOS, 3D Systems
Public
GE Internal
Macro Scale: Metal AM Processes
Direct Metal Laser Melting (DMLM) E-Beam Based AM (eBM)
Consolidation Method By Methodology
Laser Electron Beam (EB)
Gas or plasma tungsten arc
Wire feed
Powder Bed
Powder Feed
Kinetic (cold) spray
Metal Additive Mfg
Public
GE Internal
Metals AM @ GE
Feature addition & repair Large Feature fab
Powder-Bed Processes - Electron-beam or laser (~1’x1’x1’) - DMLS/DMLM: EOS, SLM Solns, Concept Laser etc. - Electron-beam melting: ARCAM - DMLM: GE Aviation is largest user in the world
Powder or Wire-Fed Processes - Electron-beam or laser - Laser: Huffman, Optomec, home-grown - Electron-beam: Sciaky
Public
Direct metal laser melting (DMLM)
Electron-beam melting (EBM)
25 GE Healthcare Summit
9/18/2014
DMLM and EBM Comparison
Laser
Melting
Electron Beam
Melting
Energy Source 400 W
Fiber Laser 3500 W Electron Beam
Scanning
Method Optical Mirrors Magnetic Deflection
Build Layers 20 to 50 µm 50 to 70 µm
Accuracy 50 µm 200 µm
Build Rate 13 cm3hr-1 55 cm3hr-1
Surface Finish 250-300 µ-in 800-1000 µ-in
Residual Stress High Low
Material Properties Drive Applications
26 GE Healthcare Summit
9/18/2014
Wrought DMLM
Horizonta
l V
ert
ical
Melt Pool Directionality Vertical Grain Growth
Similar to Wrought Isotropic / Homogeneous
Typical Equiaxed Grain Structure
Solution Heat Treatment
40
60
80
100
120
140
160
180
200
DMLS - V DMLS -
H
Wrought
Low
Wrought
High
YS (ksi) "UTS (ksi)"
18
22
26
30
34
38
42
DMLS - V DMLS - H Wrought
Low
Wrought
High
Elongation (%) "Hardness (HRC)"
GE Internal
Materials Available Metals at the ADC & GRC:
Detailed design curves available for Co-Cr, IN625 (09/13)
More materials being developed, e.g. tungsten, copper alloys
Ti64 Stainless 316L Aluminum AlSi10Mg
Cobalt Chrome Stainless 17-4PH Aluminum 6061-T6 (beta)
Inconel 625 Stainless 15-5 PH Maraging Steel MS1
Inconel 718 Stainless GP1
Ceramics:
Fraunhofer Institute of Production Technology: ZrSiO4 found to be most suitable. Other materials tried: aluminum oxide, aluminum silicate. 200W laser. 50% dense parts. Phenix Systems: Laser sintering of alumina structures. GRC
has experience
Public
Public
Manufacturing w/ AM: Current Plans • Industrial application: 19 additive fuel nozzles to be installed on every CFM
LEAP engine, >7000 sold
• GE P&W, GEHC and GE O&G launching products soon
• GE Appliances biggest prototyping user in-house – 30-40K parts/year
• Overall: Several hundred people working on AM
Pro
toty
pin
g
LEA
P f
ue
l no
zzle
sc
he
ma
tic
Public
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Emerging Apps: Tooling & Spares
Direct fabrication of metals & polymer tooling (1-2 wks):
• Polymer/silicone tooling for sheet metal forming & polymer parts
• Metal die-casting/injection molding tooling
Spares on demand (< 1 wk) • Legacy turbomachinery spares
• Bespoke parts, e.g. custom ducts
• Low-volume lots or parts made w/ hard-to-
machine materials
• Custom jigs and fixtures to facilitate
manufacturing
Ref. Stratasys Ref. Maatsura
Ref. EOS Ref.: GE led US-Army DDM IBIF Pgm. (T700 focus)
Public
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Physics-Based Modeling (PBM): Objectives
Objectives:
Understand multi-scale physics of AM processes to enable:
1) Rapid optimization of AM processing conditions for defect-free microstructure & best surface finish
2) Prediction & minimization of thermal distortion
Public
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PBM: Laser-Material Interaction • Understand laser/powder-bed interaction • Location of maximum power absorption inside the powder bed • Impact of particle size & distribution on melt kinetics • Fraction of laser power absorbed
Powder
bed height
(um)
Averaged
thickness
(um)
Beam
radius
(um)
Fraction
absorbed
Z location
abs. density
max (um)
Laser
interaction
width
(Z-size)
Interaction
radius
(um)
50 70 50 0.52 50 60 60
50 70 40 0.52 40 50 50
50 70 25 0.52 40 60 30
100 120 50 0.63 40 80 60
100 120 40 0.63 40 80 50
100 120 25 0.63 40 80 30
Public
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PBM: Laser Scanning Model
Track 1
Track 2
Cooling rate > 106/s
Sxx
Crack directions can be correlated to the max. principal stress
in the laser scanning model
Output of the model • Melt-pool size & shape • Temperature distribution over time • Stress build-up & predict crack formation
during laser scanning Helps in: • Optimizing AM process windows (process
parameters) for defect-free deposition Challenges • ~2 CPU hours to scan 0.015 cm on a
desktop workstation • Therefore, 1 cm3 solid ~ 1 700 000 CPU
hours (~200 years…)! • NAMII proposal w/ Louisville and Penn
State aimed at addressing these deficiencies
Public
PBM: Distortion Prediction
Parameter Value
Materials Co-Cr
Laser scanning speed 850 mm/s
Laser power 310 W
Laser absorptance 0.35
Ambient temperature 20 oC
Hatch spacing (Track width) 0.13 mm
Layer thickness 0.05 mm
Recoating Time 15 s
Build plate temperature 100 oC
Heat transfer coefficient
(metal/powder)
10 W/m2/K
Heat transfer coefficient (build
plate/environment)
150
W/m2/K
Part size: 1 inch × 1 inch × 1 inch
Predicted distortion
after removal from build
plate
~0.5mm
Public
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Process Qualification
Ni-alloy A Co=17.5, k=0.9, m=-11
with stray grains
Typical nodal temperature Melt pool front advance
A Process Map ( for LENS by J.Beuth et al)
Distortion prediction
Microstructure prediction
• Development of a process map will facilitate rapid part qualification through
minimization of distortion, control of melt pool shape and consistent microstructure even in overhang regions that will enable improved surface finish
Proliferation & Future Dev.
Creators & Pioneers
Early Adopters
Primary Majority
Secondary Majority
Holdouts
Adoption: What phase are we in?
Technology Maturation and Acceptance Curves
PAX NAVAIR Meeting, May 9th, 2013
Public
37 GE Healthcare Summit
9/18/2014
AM: Recent Acquisitions
November 12, 2012
GE Aviation Acquires MTI/RQM
ADC
ALL
Public
Makers Guild AN ACTIVE LEARNING PROGRAM that will inspire GE engineers to work with new
manufacturing technology through a simple and engaging curriculum comprising a series of
progressively sophisticated challenges & training seminars
Novice level Download simple CAD models /print a 3D part
Master level Access to ADC to implement a design improvement via AM
Apprentice & expert levels Design & build complex engineering parts
Courtesy: Herb Caloud, GEHC
100 Printers Deployed
1000 Guild members
Aviation, Corporate, Healthcare,
O&G, P&W, Appliances, Lighting
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Additive Manufacturing (AM) Quests OPEN ENGINEERING QUESTS DESIGNED TO
Engage and build the external AM ecosystem for design & materials
Leverage open innovation tools to accelerate NPI’s
Demonstrate GE’s continued investment in the space.
1 2 3
AM DESIGN QUEST AM PRODUCTION QUEST
• Reduce jet engine weight by redesigning
accessories components, e.g. brackets, hangers
• 650+ entries in 3 months. ID best design groups
• Build high-precision components in specialty
materials; stimulate supply chain growth
• High density, high atomic number metals
• 150 micron walls, with tolerances ±15 microns
CT Detector components
Challenges hugely successful, global response. Winners from Indonesia & Finland
GEA accessories bracket redesign
Public
AM Quests: Designing for Performance
Additive Design Quest
Production Quest
> 80% weight reduction realized
Long development times for all materials processing processes
1970 1990 2000
COMPOSITE FAN BLADE
DS CHEMISTRY AND PROCESS
2010
SC SUPERALLOYS
COMPOSITE FAN CASE
2020
POWDER METALLURGY DISKS
Ti-Al
ADDITIVE MANUFACTURING
Initial lab development
Committed to engine
Entry into Service
1980
Aviation Materials & Manufacturing Dev.
Public
Improving machines
Headwinds Tailwinds • Early feasibility of AM
established @ GE
•Multiple machine producers, more competition, willing to customize •Game changing, high performance
products emerging in aerospace & power-gen industries
•Materials qualification expensive; 5+ years to qualify one material •Custom machine expensive; machine
producers are small & cannot support multiple development efforts
• Inspection methods not available
Distortion a problem; costly iterations
Future: Challenges
Public
Additive Manufacturing Development
Technology needs are broad and requires a joint effort between
industry, government & academia
Adaptive,
reconfigurable
manufacturing • Custom & Location
Specific Materials
• Rapid Material
Qualification
• Design freedom
Technolo
gy D
evelo
pm
ent
2-3 years 5 years + Today
One-off manufacturing • Small Supplier Base
• Few Industry Specifications
• Limited Design Methodologies
• Productivity Enhancements
• Expanded Material Databases
• Process Monitoring & Control
• Robust manufacturing systems