GKN Aerospace Additive Manufacturing
Rob Sharman – Head of Metallics Technology
Societe Generale 2014
1
Additive Manufacturing Terminology
The ASTM definition:
LDW
“The process of joining materials to make objects from 3D model
data, usually layer upon layer, as opposed to subtractive
manufacturing methodologies, such as traditional machining”
DMLS
DMD
SLA
SLM LENS WAALM
3D-Printing LC
ALM
FDM SLS
EBFFF
EBM
Polyjet
2
Additive Manufacturing
DEPOSITION
PLASMA
EB
LARGE PUDDLE
DEPOSITION(WIRE)
(WIRE)
DESIGNATED
ICON
EB
P
POWDER BED
LASER
LASER
SMALL PUDDLE
(WIRE)DEPOSITION
(POWDER)
L
L
LASER
LASER
P/BED
(POWDER)
L
EB
EB
P/BED
(POWDER)
BINDER
INDIRECT
P/BED
(POWDER)
EB
B
Arcam
PICTURE
Sciaky
GKN
Aerospace
Fraunhoffer ILT
Fraunhoffer ILT
Reis
Robotics
DESCRIPTION
APPLICATIONS
Free deposition of
Deposition of powder
Deposition of wire fused using electron
wire fused using
fused using laser in a
or laser beam in a chamber to produce
• Lower material throughput
plasma
arc to throughput
chamber to produce
• High material
part
deposition systems
produce
part
part
deposition
systems
Laser or electron beam selectively
• Lowest
Lowinmaterial
fuses powder on a•bed
a
material
thruthru-put
chamber to produce part
put
• Ti6Al4V
•
Focus
on
Ti
and
Ni
alloys
• Focus on Ti
Cranfield
• Ti, Ni and steel
University
• Highly netalloys
• Nearer net-shape add-ons and
• Large-scale pre-forms
shape
prismatic pre-forms
•
Nearest-net
Cranfield
• Initial cost-driven
introduction
• Small –
University
• Engine component fabrication,
•
Intricate
himedium
• Applications including largeCranfield
aeroUniversity component repair and grow-outs (cost
TWI
value
prismatics GKN
structure components
& performance)
Aerospace
components
GKN
Aerospace
GKN Aerospace
• Structural
• Broad range of medium-size engine
• Engine parts
brackets,
TWI
High
complexity
enables
High material fusion rate and deposition technique
enablecomponents;
and structures
and geometric
small
engine
partsnext
Accurate
but
near-net
generation
small
prismatic
components.
large scale near-net shape parts or grow-outs
fabrications
inserts
and fabrications
parts and claddings
3
Virginia Tech
Powder / binder
system
requiring
• Low material
down-stream
thru-put
consolidation
• Cast-able
alloys
• Highly netshape
• Complex
castings and
Höganäs Digital Metal®
inserts
Net-shape
parts
•Engine
parts
achievable
at
and
automotive
rates
fabrications
History & Lifecycle of Technology Adoption
CNC Machining (Subtractive)
Robotic
process
reaches
manufacturing
maturity
Over 40 Years!
Applied
across
multiple
industries
NC Machine
Invented
1930
1940
Fiberglass
Patented
Composites
1950
Carbon Fiber
production
begins
1960
1970
All fiberglass
aircraft;
H-301
Dragonfly
1980
1990
Metallic AM
Over 40 Years!
Entire history of AM!
2000
2010
787
commercial
aircraft first
flight
Gartner Hype Cycle
4
Ti Growth in Airframe Applications
Of particular note in recent years has been the rapid growth of Ti and its alloys in airframe
applications
This has been predominately linked to the growth in CFRP due to the better compatibility of
Ti alloys (galvanic corrosion and thermal expansion) with CFRP
Growth in use of Ti in Aerostructures
5
AM within Processing Portfolio
Cost Drivers
Delivery Drivers
Conventional
Data Release
Performance Drivers
Tooling 1st Article
Ready Production
DfM
Complete
< 95
WEEKS
< 12
WEEKS
AM
AM ONLY
AM IN COMPETITION WITH OTHER TECH
DEPOSITION
DEPOSITION
POWDER BED
Deposition
P
Powder Bed
EB
L
L
L
EADS
Norsk Titanium
6
EB
GKN
AM Adoption
Cost Reduction - Aero
Niche/High Performance - Aero & Auto
Near net pre-forms
DERIVATIVE
SIMILAR
Added features
NEW
Improved functionality/performance
Introduction of both new materials and processes is challenging
SECONDARY
PRIMARY
Conservatism and healthy cautiousness are barriers to initiatives
Step-wise approach is implicitly required
“INITIAL” phase
Generally cost-driven implementation
Allows both GKN and customer (and supply chain) to acquaint
themselves with challenges and opportunities
“NEXT” phase
Builds on “INITIAL” phase
1
Allows all parties to fully exploit AM technology benefits
7
Generic Conventional Component
8
Generic Conventional Component
 Mat’l = 1.08kg
 Mat’l = 4.85kg
 Swarf = 0.31kg
 Swarf = 4.08kg
Machining Route to Man’f
AM Route to Man’f
 Part = 0.77kg
9
Generic Conventional Component
 ~5 x less feed stock
 ~13 x less swarf
 Conventional design (not yet
optimised for weight)
10
AM
R&D
Programmes
GKNCurrent
Additive
Manufacturing
The possibilities and benefits are exciting
Unlocks Materials Science
Only uses the material you need - uses less material
Design no longer constrained by conventional manufacturing processes
Allows design for functionality
Speed and flexibility of development
A revolutionary set of technologies – not evolutionary
Phased introduction is implicitly required
Secondary derivative structure before primary optimised
Need to pin variables to gain acceptance
Process and material are now linked like never before
Big challenge to the industry in evaluation
How to certify
New and novel QA techniques required
11
GKN Investment and Growth in Additive Manufacturing
GKN sees additive manufacturing as a high priority technology
GKN is investing and expanding our portfolio in AM across the business,
leveraging our expertise across divisions
GKN is expanding and establishing new Centres of Excellence in additive
manufacturing, building on existing capability to build a global network:
Powder bed
-
Filton (UK)
High rate Deposition
-
St Louis (USA)
Fine Deposition
-
Trollhatten (Sweden)
Materials
-
New Jersey (USA)
Operating across the whole value chain, from raw material, design, process
and application
Partnered with key academic institutions, customers and suppliers
Understand the criticality and potential of design, and GKN is developing the
skills and design toolbox to take advantage of the disruptive nature of additive
manufacturing
12