Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond JGIF 2015 Tokio, 9th of November 2015 Joachim Zettler – Airbus Apworks GmbH
Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
Airbus APWorks
Founded in 2013
100% subsidiary of Airbus Group
A perfectly harmonized triad for 3D printing Design
Materials
Serial production
Who we are: Founded in 2013 as a 100% subsidiary of Airbus Group, APWorks is familiar with modern manufacturing processes, including proven concepts and lightweight design from the aerospace technology. With a high focus on design, materials and serial production, APWorks optimizes parts for weight, structure, cooling and RF efficiency. Working in close cooperation with Airbus, we develop high quality materials, and advanced qualification processes for serial production. Our aim: Making innovative and high quality aerospace concepts accessible for customers across all industries.
Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
Airbus APWorks
Founded in 2013
100% subsidiary of Airbus Group
A perfectly harmonized triad for 3D printing Design
Materials
Serial production
Our customers: We are globally operating and have a global customer base. Ranging from aerospace, automotive, oil&gas to robotics and mechanical engineering, there is nearly no industry we do not offer specific solutions for.
Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
Airbus APWorks
Founded in 2013
100% subsidiary of Airbus Group
A perfectly harmonized triad for 3D printing Design
Materials
Serial production
Where we are: Located near Munich, Germany, at the Ludwig Bölkow Campus, which pools high technology initiatives together, APWorks is situated in close proximity to AIRBUS Group divisions and other high tech companies such as IABG, EOS and Siemens. This setup allows easy access and interchange on the latest technologies and trends in the fast growing additive manufacturing business.
AM VALUE CHAIN Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
Additive Manufacturing
APWORKS OFFER Process & Post Process
AM Design
AM Value Chain
End of Part‘s Life
Quality Assurance
AM VALUE CHAIN Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
Additive Manufacturing
APWORKS OFFER Process & Post Process
AM Design Build design & preparation Detailed design, optimization Process selection Part concept
AM Value Chain
Repair
End of Part‘s Life
Material prodcuction & qualification ALM process Heat & pressure treatment Machining of interfaces Surface treatment
Destructive testing NDT (non-destructive testing) Metrology Validation on testing
Quality Assurance
AM VALUE CHAIN Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
Additive Manufacturing
APWORKS OFFER Process & Post Process
AM Design
APWorks controls each phase of the AM value chain with customized services generating superior results: • Concept Development & Consulting • From prototyping to large scale part production • Powder Sales of high quality Aluminum powder (Scalmalloy®) • System integrator
End of Part‘s Life
Quality Assurance
Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
Re-cap: ALM Deposition Process Types
Additive Manufacturing Processes
Powder Bed
Directed Deposition
Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
Motivation for Technology Adoption
• Weight Savings by Topology Optimisation
Titanium Price Titanium Plate
90% Waste
• Unique Geometric Capability for functional applications • Material Price Volatility • Material Waste in Manufacturing
QUALITY
COST
Data Release
• New Material Compositions
DFM complete
Dies / Pattern complete
Forging / Investment Casting Up to 95 wks for large/complex parts
TIME Programme Risk Mitigation
AM ~12 wks
Opportunity for design changes or risk mitigation
First Production article
AM VALUE CHAIN Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
ALM value chain in more detail Design optimization
1
2 Existing design
Further loop of Topology optimization if required
Data used to create optimized design interpretation
Further FE analysis 4
Design interpretation modelled as solid 3
AM VALUE CHAIN Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
DETAILED DESIGN, OPTIMISATION, DFM
ALM value chain in more detail Detailed design, optimization, design for manufacture (DFM)
Although not yet applied to ALM applications; AGI has capability for RF simulation
Design for manufacture
Application of design rules (design for manufacture)
Structure efficiency
Aerodynamic efficiency
Cooling efficiency
antenna pattern distortion
Structure simulation
Flow simulation
Thermal simulation
RF simulation
Design rules to applied on their own or in conjunction with optimisation
AM VALUE CHAIN Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
MATERIAL
ALM value chain in more detail Scalmalloy®
Scalmalloy®
AlSi10Mg
TiAl6V4
0.2% Offset Strength (MPa)
450
210
860
Tensile Strength (Mpa)
490
350
910
Specific Strength
184
129
205
8
3
10
Vickers Hardness HV0,3
177
119
320
Fatigue Limit 3E7 cycles (MPa)
300
97
600
Density (g/cm3)
2.67
2.70
4.43
Typical Values
Elongation (%)
Scalmalloy® ALM parts have properties in the range of high strength 5XX Al-Alloys
AM VALUE CHAIN Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
ALM value chain in more detail Process & Postprocess MATERIALS & MACHINES
EOS M280
EOS M270
SLM 125 HL
ARCAM A2 EBM
Available Metallic Materials: • Titanium (Ti6AI4V) • Stainless Steel (316, 17-4PH, 15-5PH) • Aluminum AISi10Mg, Scalmalloy®, Silmagal® • Cobalt Chrome • Inconel 718, Inconel 625
EOS M290
EOS M400
AM VALUE CHAIN Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
DESTRUCTIVE TESTING OF TRAVELER
ALM value chain in more detail Destructive testing of traveler specimens
Testing of inbuild traveler samples
Cross reference against extensive Airbus Group APworks database • Static/dynamic tensile • Fatigue crack propagation • Fracture toughness, JIC, etc. • Corrosion (salt spray, SCC etc.) • Fracture analysis (SEM, XPS, XRD etc.) • AFGROW, DoE, ANOVA etc
Analysis of traveler samples
AM VALUE CHAIN Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
NDT
ALM value chain in more detail Non-Destructive Testing Detection & characterisation of flaws
Analysis in reference to effects of defects catalogue
Residual Stress Measurements • X-ray diffraction (XRD) with portable system • Destructive hole drilling method
µCT testing of a cube: Detection & characterisation of voids (Voxel size: 20 µm)
Defect characterisation: (µ-) Computed Tomography
Defects: Ultrasonic
Defects: X-Ray
Residual stress
Use Cases Additive Manufacturing
Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
Solutions for Aerospace Industries
Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
Weight savings on an armrest out of Scalmalloy®
255g
44% Weight saving
142g Material: Al2024
Material: Scalmalloy®
Homogenized stress distribution Increased stiffness
Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
Impact of the lightweight armrest (Calculated on one Airbus A320 per year)
27.12kg
4.2t
$ CO2
1260 €
13.2t
Weight saving
Kerosene saving
Kerosene cost saving
CO2 saving
Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
Weight Saving through Design Freedom: ‘Bionic’ Brackets
0.89
0.35
KG
KG
836
429
MPa
MPa
Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
Solutions for General Mechanical Engineering
Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
Heat exchanger demonstrator Combining lightweight and functional integration
Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
Heat exchanger demonstrator Combining lightweight and functional integration
No support structure needed for printing
Minimal pressure loss
Extraordinary thermal performance
Scalable design
Very large surface area
Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
Use Cases - Stem
272 g
Material: Scalmalloy®
Material: 6XX Al
G
Weight saving
198 g
Homogenized stress distribution
G Increased stiffness
Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
Use Case – Bionic frame
6kg Weight of the Frame Structure Material: Scalmalloy® Bionic Frame
40% Weight Reduction
Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond
Thank you for your attention
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