Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond

Additive Manufacturing applications in Aerospace, Automotive, Robotics and beyond JGIF 2015 Tokio, 9th of November 2015 Joachim Zettler – Airbus Apwor...
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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

[email protected] +49 89 607 28237

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