Additive Manufacturing

Amy Elliott Graduate Researcher

Manufacturing Demonstration Facility

SPARK Oak Ridge, Tennessee November 19, 2013

Manufacturing Demonstration Facility

Additive Manufacturing

Roll-to-Roll Processing

Carbon Fiber & Composites

MDF
Manufacturing Demonstration Facility:
a multidisciplinary DOE-funded facility dedicated to enabling demonstration of next-generation materials and manufacturing technologies for advancing the US industrial economy www.ornl.gov/manufacturing Transient Field Processing LowTemperature Material Synthesis Lightweight Metals Processing

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Intro. to Additive Manufacturing (AM)

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Additive Manufacturing will become the most important, most strategic, and most used manufacturing technology ever.
Wohlers 2012
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Topics to Discuss: ! Principles of AM ! Powerful Applications of AM ! AM Thrust Areas at MDF ! Unique AM Capabilities at MDF

Additive Manufacturing (AM)

!"#$%&'()$*&$+,-./01)$+12*!

Topics to Discus: ! Principles of AM ! Powerful Applications of AM ! AM Thrust Areas at MDF ! Unique AM Capabilities at MDF

Additive Manufacturing will become the most important, most strategic, and most used manufacturing technology ever.
Wohlers 2012
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Principle 1: Complexity is Free

Withinlab.com Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc.

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Principle 2: Variety is Free

goyaldiecast.com Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc.
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Principle 3: No Assembly Required

www.austechexpo.com.au

replicatorinc.com

Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc.

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Principle 4: Zero Lead Time

Makepartsfast.com Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc.
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Principle 5: Zero Skill Manufacturing

Makerkids.ca Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc.
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Principle 6: Zero Constraints

Bathsheba.com Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc.

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Principle 7:

Compact, Portable (Affordable) Manufacturing

Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc.

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Principle 8: Less Waste

Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc.

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Principle 9: Infinite shades of Materials

Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc.

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Principle 10: Precise Replication

Makerbot.com Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing. Indianapolis, Indiana: John Wiley and Sons, Inc.

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Enabling Next Generation Robotics

Additive Manufacturing

Army PETMAN program

! Team with Boston Dynamics to develop a fully anthropomorphic android for in situ testing of chemical and biological PPE
! ORNL role: Arms and hands ! Requirements: Integrated sensing (chemical), perspiration, thermal management and control (hydraulics) ! Part complexity would not be possible with conventional machining

Bluefin Robotics ! Develop a neutrally buoyant titanium manipulator arm

! Able to float ! Integrated fluid passages and wire ways

Anthropomorphic Hydraulic Arm for Boston Dynamics Petman Program

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Enabling Next Generation Robotics

Additive Manufacturing

Pistons integrated into structure Curved fluid passages

Integrated motor and pump

! Titanium made using E-beam AM (operating pressure 3000 psi) ! Integrated pump, fluid passages and pistons with mesh for weight reduction
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Enabling AM of Aerospace Brackets

Collaboration with Industry

! Bleed Air Leak Detect (BALD) Brackets

! Buy to Fly Ratio of 33:1 ! AM can reduce to 1.5:1

! ARCAM Parts HIPed (900oC, 15ksi, 2 hours) ! Decrease Cost by Over 50%

Pores

As-Deposited

As-HIPed

Property Ultimate Tensile Strength, (ksi, MPa) Elongation, %

Consistent with 17 SPARK Additive Manufacturing data from ARCAM

Minimum Value 132 12 910

Maximum Value 152 22 1,048

Over 60 Tensile Specimens Tested Within a Matrix of Processing Conditions

Enabling AM of Turbine Blades

Science to Application

! Optimized internal cooling structures are desired for maximum efficiency ! AM can produce geometries not possible with conventional processes ! Decrease manufacturing costs while maximizing performance
turbine blade Reconstructed image using neutron tomography

Headquartered in Cincinnati, OH

! Largest number of AM machines worldwide ! 18-yrs experience in laser deposition ! Works with every major aerospace company in US

Critical to widespread adoption of technology

Understanding link between residual stress and additive manufacturing

laser AM of turbine blade

Utilizing neutron science to impact industry

Laser AM creates large residual stress leading to distortion

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Profilometry map illustrating distortion

Additive Manufacturing (AM)

Thrust Area Goals

Leveraging key resources at ORNL to accelerate technology implementation ! Developing advanced materials
! Titanium alloys, Ni superalloys, stainless and ultra highsteels ! High-strength, carbon-reinforced polymers

! Implementing advanced controls

! In-situ feedback and control for rapid certification and quality control

! Understanding material properties and geometric accuracy ! Exploring next-generation systems to overcome technology barriers for manufacturing
! Bigger, Faster, Cheaper ! Integrating materials, equipment and component suppliers with end users to develop and evolve the supply chain
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Neutron Characterization of AM
Unique Capabilities

Neutron Imaging and CT

! Neutrons offer higher contrast and better resolution than x-rays ! Resolution Capabilities ! Currently at HFIR: 50 !m ! Proposed VENUS: 10 !m ! Ability to study micro/macro cracking phenomena related to residual stress during processing
Reconstructed image using neutron tomography

laser AM of turbine blade

! Successful Inter planer spacing measurements on complex geometry ! Developing capabilities for residual stress mapping ! In-situ measurement during processing, HT, mechanical testing

Residual Stress Measurements

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Neutron Characterization of AM
Unique Capabilities

! 210 Images around 180 degree rotational axis ! Currently 50-75 m resolution at HFIR, VENUS is targeting 10 m ! Developing methodology to perform stress mapping with tomography

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MDF Metal-based Systems

Additive Manufacturing
Electron Beam Melting Ultrasonic Additive Manufacturing Laser Metal Deposition Laser Powder Bed

! Developing in-situ characterization, feedback and control ! Heated powder bed ! Expanding range of materials (Ti64, 718, 625, CoCr) ! Precision melting of powder materials

! Simultaneous additive and subtractive process for manufacturing complex geometries ! Solid-state process allows embedding of optical fibers and sensors

! Site-specific material addition ! Application of advanced coating materials for corrosion and wear resistance ! Repair of dies, punches, turbines, etc.

! Unheated powder bed ! Wide range of material choices (316L, 17-4PH, H13, Al, Ti, 718, 625) ! 9.8 x 9.8 x 11.8 inch build volume ! Precision melting of powder materials

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MDF Polymer-based Systems

Additive Manufacturing
Fused Deposition Modeling Photopolymer Multi-head Jetting Big Area Additive Manufacturing (BAAM)

! Development of highstrength composite materials for industrial applications ! Precision deposition of thermoplastic materials ! Multi-material deposition

! Deposition of multiple materials, integrated structures, and material gradients ! High resolution, complex geometries, and smooth surface finish

! Large build volume ! Currently 8 x 8 x 8 ft ! Expanding to 20 x 10 x 10 ft ! Pellet to part manufacturing ! 10-20 lbs per hour throughput ! Amorphous & semi-crystalline materials

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Big Area Additive Manufacturing (BAAM)

Large scale deposition system
! Unbounded build envelope ! High deposition rates (~20 lbs/h) ! Direct build components ! Tools, dies, molds

Carbon fiber material reduces warping out of oven

ABS
CFABS

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SSAM Lab
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! ! ! !

Small Scale Additive Manufacturing

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Carbon Fiber FDM Composites

! Compounded filament printed on Solidoodle 3 (modified) ! 10-15% CF by weight
ABS
B CF-A S

ABS

Lindahl ACCE Poster (2013)

Dramatically reduced curl CF-ABS 2x strength 4x stiffness ABS CF-ABS

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Multi-function Material Systems

Manufacturing Systems ! ! ! ! ! Integrate Functionality into Structure Electrical Circuits Sensors Communication Energy Generation Energy Storage

Optomec/Neotech/FAPS

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Key Principles of Additive Manufacturing

Complexity is Free Variety is Free No Assembly Required

Less Waste

Infinite Shades of Materials

Zero Constraints

Others: Zero Lead Time, Compact and Affordable, Low-skill, Precise Replication
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Discussion
Amy Elliott elliottam@ornl.gov (865) 946-1577

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