Non-Destructive Evaluation Techniques for Additive Manufacturing
Donald Godfrey – Engineering Fellow – Honeywell International
Mark Cola – President and CEO – Sigma Labs, Inc.
This document and all information and expression contained herein are the property of Honeywell International Inc., are loaned in confidence, and may not, in whole or in part, be used, duplicated, or disclosed for any purpose without prior written permission of Honeywell International Inc. All rights reserved.
Honeywell’s Businesses Automation & Control Solutions Minneapolis, MN headquarters
Aerospace Phoenix, AZ and Rolle, Switzerland headquarters
$14.5B $15.8B*
$10.2B
• $40.5B in sales* • Approximately 132,000 employees, 1,300 sites, 70 countries • Morristown, NJ global corporate headquarters
Performance Materials & Technologies Morristown, NJ headquarters * 2014 sales : ex-4Q14 OEM Incentives
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Aerospace Thousands of Honeywell Aerospace products and services are found on virtually every commercial, defense and space aircraft and its turbochargers are used by nearly every automaker and truck manufacturer around the world.
The Aerospace business unit develops and integrates technologies that span air traffic modernization, flight and runway safety, engines, cockpit and cabin electronics, connectivity, logistics and more that deliver safe, efficient, productive and comfortable transportation-related experiences.
Possibilities. Made Easy. Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
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About Aerospace AEROSPACE FACTS • Headquartered in Phoenix, Ariz. and Rolle, Switzerland • Approximately 42,000 employees • Nearly 110 worldwide manufacturing and service sites • Total Revenue of $15.8 billion in 2014* STRENGTHS • Global leader in the aviation industry • Developing innovative safety products • Driving modernization of global air traffic management • Revolutionizing combat technology • Committed to improving operational efficiencies • Serving all major automotive OEMs worldwide
($B)
SALES
* Ex-4Q14 OEM Incentives
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Phoenix Engines Site Overview Key Facts: • ~50 years of building propulsion systems • > 80,000 auxiliary power units produced • > 40,000 engines produced Key Customers: • Airbus Assembly & Test Facility • Bell • Boeing • Bombardier • Cessna • Dassault • General Atomics • Gulfstream • Sikorsky • US Military Services • Foreign Military • Other Govt Agencies
Engines Campus
Gear Line Facility
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Honeywell HTF7000 Engines • Historical deliveries - >1000 HTF7000 Integrated Propulsion Systems delivered and in service - >2.2 million flight hours to date - Four HTF7000 models in the family: › HTF7000 for Bombardier CL300 › HTF7350 for Bombardier CL350 › HTF7250 for Gulfstream G280 › HTF7500 for Embraer Legacy 450/500
Challenger 300 Bombardier Challenger 300
• HTF7K Integrated Propulsion System: Challenger 350
- Turbofan engine - Nacelle - Thrust reverser - ~7000 - 7500lbf Take-off thrust (nominal)
• Applications & Entry Into Service Dates - Bombardier CL300 – In service since 2004 - Gulfstream G280 – In service since 2012 - Bombardier CL350 – In service since June 2014 - Embraer Legacy 500 – In service since September 2014 - Embraer Legacy 450
Gulfstream G280
Embraer Legacy 450/500
>1000 HTF7000 IPPS Delivered– 5 Applications – 2M Fleet Hours Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
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Additive Manufacturing Technology Center Benefits of Additive Manufacturing • Rapid prototyping – development lead-time reduction • Design freedom – high complexity, low volume • Target markets in Aerospace: - Commercial Aerospace, UAVs, electronic housings - Engine components, hinges & brackets, housings - Spacecraft components
Honeywell Phoenix Focus • Material and process development • Prototype fabrication
External Collaboration Underway • Air Force – Materials Affordability Initiative - High temperature Alloys
• DARPA – Integrated Computational Materials Engineering (ICME) related • Universities
Developing World Class Additive Manufacturing Capability Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
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Aerospace Engine Platforms • Wide spectrum of Aero Turbine Products
Over 150,000 Turbine Engines Delivered to Customers © 2014 by Honeywell International Inc. All Rights Reserved. Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
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Additive Manufacturing at Honeywell • Mission: To be an industry leader in deployment of AM - Metals - Polymers • Honeywell Views Technology as Game-changer Type of Technology - Allowing Honeywell to: Reduce costs of some components Optimized Design Shorten supply chain
Shorten engineering development cycle time
Honeywell is Committed to Additive Manufacturing Growth © 2014 by Honeywell International Inc. All Rights Reserved. Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
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Past Honeywell Powder Bed Metal AM Efforts
Initial development of prototype parts with Morris Technologies
2007
DMLS 718 swirler on Airbus flight test bed
2008
2009
2010
DMLS 718 Tangential On Board Injector on flight test bed
2011
2012
2013
2014
Began building internal R&D lab for AM and production planning
Success with AM Drives Technology Integration © 2014 by Honeywell International Inc. All Rights Reserved. Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
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Honeywell Components Fabricated - Powder Bed AM
Various Part Complexities and Materials Produced © 2014 by Honeywell International Inc. All Rights Reserved. Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
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Honeywell Global Footprint with AM Labs
Phoenix
Brno Shanghai Bangalore
• Aerospace/AME leads the initiative • Leveraging global Honeywell presence Utilize Global AM Presence for Speed and Cost © 2014 by Honeywell International Inc. All Rights Reserved. Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
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Design for Additive Manufacturing • AM design flexibility - Reduced weight - Increased efficiency - Improvements in component life
Original Design
Redesign with AM: 56% weight reduction while maintaining required strength
Additive Manufacturing Is Changing The Design Culture © 2014 by Honeywell International Inc. All Rights Reserved. Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
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Objective Evidence Sigma Labs Honeywell International Working Together to Build an in-process NDE System for:
Objective Evidence of Compliance to Design Intent
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Process Monitoring - DARPA • Ensuring quality during build important for Part Quality - Metallurgical Properties: PrintRite3D® INSPECT™ Melt pool monitoring and defect recognition
- Geometric Properties: PrintRite3D® DEFORM™ Dimensional variations and resolution accuracy of at least 100μm
- Coating issues • Utilizing a sensor array - Camera monitoring - Photodiodes and Pyrometers - Power meters
Copyright © 2014 Sigma Labs, Inc.
Advancing In-Process Monitoring to Meet Quality Needs © 2014 by Honeywell International Inc. All Rights Reserved. Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
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Honeywell / Sigma Labs Technology Development
PrintRite3D® DEFORM™ Initial Resolution Analysis
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Design Intent
PrintRite3D® INSPECT™
PrintRite3D® DEFORM™
Goal: Objective Evidence of Compliance to Design Intent Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
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PrintRite3D® DEFORM™ Real-time geometric property measurement software
• Layer-by-layer geometric property measurements. • Provides for comparison of ‘asbuilt’ to original digital CAD model ‘should be’. • In development with Honeywell
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Application of PrintRite3D® to DMLS® Avoids x-ray CT and CMM through use of in-situ geometric measurements
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Geometry
215 μm shoulder
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Extract circular hole geometry
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Extracted geometry details
Chamfered layers ignored
11.57 mm dia. (nom)
215 μm shoulder
11.14 mm dia. (nom)
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11.14 mm 11.57 mm dia. (nom) (nom)
Diameter of least squares fit circles
Mean diameter: 11.61 mm (0.46 in.)
11.16 mm (0.44 in)
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Current DEFORM™ feature resolution
At least 215 μm
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11.57 mm dia. (nom)
Mean 11.61 SD 0.06 mm
11.14 mm (nom)
Diameter distribution
Mean 11.16 mm SD 0.06 mm
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Compare DEFORM™ to specification
Small diameter: Spec: 11.14 mm ± 0.01 mm DEFORM™: 11.16 mm ± 0.06 mm Big diameter: Spec 11.57 mm ± 0.09 mm DEFORM™: 11.61 mm ± 0.06 mm
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DEFORM™ vs. standard techniques
Measures (Inches)
Top hole shoulder ID Base width
Center nub to top of bracket
Top hole centers
Shoulder Width
Top hole ID
1.998
0.43
0.4383
3.7
0.218— 0.226
--
1.00
OCMM
1.997
0.4386
0.4556
3.76
0.222
1.34
1.0
CT*
2.01
0.44
--
3.78
0.22
--
1.0
DEFORM
TBD
0.44
0.46
TBD
TBD
TBD
TBD
Engineering Drawing
Base ID
*CT artifacts precludes an accurate measure Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
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Current DEFORM™ Capabilities
Initial geometry resolution: at least 215 μm Measurement error: 60 μm Goal: Objective Evidence of Compliance to Design Intent Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
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Summary • Honeywell incorporating AM on Global Scale • Working to be world leader in technology development in the area of in-process NDE for AM • Objective Evidence of Compliance to Design Intent is the ultimate goal
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Special Credits For Team Members
Sigma Labs
David Clark Alberto Castro
Honeywell International Brian Baughman
© 2014 by Honeywell International Inc. All Rights Reserved. Honeywell Confidential. Use or disclosure of information on this page is subject to the restrictions on the title page.
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