additive manufacturing at ge
DESCRIPTION
AM at GETRANSCRIPT
Imagination at work.
Greg Morris
Additive Manufacturing at GE
Who We Were…Who We Are
Page 3 7/27/2014
Pre-GE Acquisition
MTI & RQM
Founded 1994
Introduced DMLM to NA in 2003
135 employees
Services included:
Engineering & Design
Additive (Metals/Polymers) (25 additive machines)
Post-Processes (Machining, Thermal Processing, Finishing)
Collaborations/JV’s…i.e. MicroTek Finishing w/BinC, etc.
Customer Base: Aerospace, Medical, Consumer Goods, Energy
Page 4 7/27/2014
Additive Development
Center - GEA focus - Other GE - Select Externals
Additive Lean Lab /
Pilot Production - Low rate initial production
GE Acquisition of MTI & RQM (Nov 2012)
Page 5 7/27/2014
Manufacturing Technology Development
TRL / MRL 0 TRL / MRL 3 TRL / MRL 9 TRL / MRL 6
ID New Technologies
Support Production
Technical Feasibility
Develop
Technologies Mature Technologies
GRC
Additive Development Center (ADC)
Additive Lean Lab (ALL)
Production
Material Development Physics Models Early Process Dev
Material Development Machine Development
Process Development ------------------------- Test Fixture/ Tooling Mfg Prototype Manufacturing Test Article Manufacturing Pre-Production Mfg
Early Production Mfg Product VSE Production Process Dev
Low Rate Manufacturing
Final Production Site (Auburn, AL)
High Rate Manufacturing Entitlement Cost
DMLM (Today)
How the Process Works...
GE Proprietary Information
3D CAD Model
AM Process Thermal
Processing
Post Processing
and Inspection
Final Part
Prep for Process
Basic Process (DMLM)
Additive Manufacturing at GE | July 2014
Additive Modalities
GE Proprietary Information
Export Authorization, ECCN: 9E991, NLR
Types of Additive
Rapid Prototyping? Additive Manufacturing? 3D Printing?
Photo Courtesy: EOS
Photo Courtesy: Stratasys Photo Courtesy: Stratasys
Photo Courtesy: Stratasys
Photo Courtesy: 3D Systems
Photo Courtesy: Arcam
GE Proprietary Information
Export Authorization, ECCN: 9E991, NLR
Polymers - SLA
Photos Courtesy: 3D Systems
GE Proprietary Information
Export Authorization, ECCN: 9E991, NLR
Polymers - SLS
Photos Courtesy: EOS
Photos Courtesy: Materialise
GE Proprietary Information
Export Authorization, ECCN: 9E991, NLR
Polymers - FDM
Photos Courtesy: Stratasys
GE Proprietary Information
Export Authorization, ECCN: 9E991, NLR
Polymers - PolyJet
Photo Courtesy: Stratasys
GE Proprietary Information
Export Authorization, ECCN: 9E991, NLR
Metals
Photo Courtesy: ORNL
Photos Courtesy: Within Labs
Photo Courtesy: EOS
GE Proprietary Information
Export Authorization, ECCN: 9E991, NLR
Nano Additive Mfg.
Photos Courtesy:
GE Proprietary Information
Export Authorization, ECCN: 9E991, NLR
Other 3D Printing
Photo Courtesy:
Additive at GE Aviation...
GE Proprietary Information
GE Aviation Additive:
SLA: (2) 500’s, (2) Vipers (3) ProJet 3500
ARCAM: (8) A2(xx)
FDM: (1) Fortus 900
PolyJet: (1) Connex 500
EOS: (11) M270’s (4) M280’s SLM: (2) 250HL
Photos Courtesy: 3D Systems, Stratasys, EOS, SLM
C-L: (1) M2
Phenix: (1)
GE Proprietary Information
GE Aviation Additive Support:
Multi axis milling
Multi axis Turning
Airflow test stand
CMM/Laser Scan 5-axis EDM Hole Drill Wire EDM
Extrude Hone
CAD Modifications
GE Proprietary Information
Production Prep:
DMLM: (7) M270’s
Thermal Processing: (1) Vacuum Stress, (1) HIP
Powder Size Analysis
Inspection
Design Matters...
GE Proprietary Information
Design to the Process Critical
GE Proprietary Information
Instrument Probe - 2005
GE Proprietary Information
Instrument Probe - 2007
• Successful builds (no crashes)
• Less cost to produce
• Higher test life
• More accurate probes
• Lower number of probes required
• Better data collection
• Shorter fabrication time
Copyright 2014 General Electric Company, U.S.A.
GE Proprietary Information
Design For Additive
Makers Guild Corporate initiative to gain exposure and expertise in the world of 3D printing Learn about:
• Build orientation • Shape capability • Support structure
Original design Example entry
Crowdsourcing Design Challenge Public challenge to find new design strategies
for additive manufacturing 150 entries in less than 30 days Top designs will
be manufactured and tested by GE
Topology & Shape Optimization
GE Proprietary Information
Design Challenge and the Potential of Additive
Tapped into 750k+ online community Over 700 entries received Many submissions over 80% weight
reduction
Traditional Design
GE Proprietary Information
GE Proprietary Information
Parts Grown and Tested
7/27/2014
Winning Design
Materials are the Reason Why…
GE Proprietary Information
Export Authorization, ECCN: 9E991, NLR
Inco 718
Inco 625
SS 316L
W Ti64 MS-1
Cu AlSi10
Mg
6061 T6
CoCr HastX
17-4 PH
SS 15-5
Ti 6242
• Super Alloys (2005)
• Many similar to wrought strengths
• Some materials characterized
• Large opportunity for novel alloy development
Material Properties Drive Applications
TiAl
GE Proprietary Information
Export Authorization, ECCN: 9E991, NLR
Material Properties Drive Applications
Wrought DMLM
Horizonta
l V
ert
ical
Melt Pool Directionality Vertical Grain Growth
Similar to Wrought Isotropic / Homogeneous
Typical Equiaxed Grain Structure
Solution
Heat Treatment
40
60
80
100
120
140
160
180
200
DMLS - V DMLS - H WroughtLow
WroughtHigh
YS (ksi) "UTS (ksi)"
18
22
26
30
34
38
42
DMLS - V DMLS - H WroughtLow
WroughtHigh
Elongation (%) "Hardness (HRC)"
ASTM
ASTM
ASTM
ASTM
GE Proprietary Information
Export Authorization, ECCN: 9E991, NLR
Material Properties Drive Applications
Wrought DMLS
Horizonta
l V
ert
ical
Typical Alpha + Beta
Widmanstatten Structure Finer than
DMLS or EBM
EBM
Similar to DMLS
Alpha on Deposition Layer
100
120
140
160
180YS (ksi) "UTS (ksi)
ASTM
ASTM
0
5
10
15
20
25
30
35
Elongation (%) "Hardness (HRC)
ASTM
ASTM
After the Build…the Role of Post Processes
GE Proprietary Information
Machining
Special Processes Surface
Finishing
Metallurgical Lab
Thermal Processing
Additive Metal Challenges…
GE Proprietary Information
Build Learnings
GE Proprietary Information
Witness Line due to a power outage
GE Proprietary Information
EBM ‘Cake’ – Limit of Internals
7/27/2014
How GE Aviation is Using Additive Metals
GE Proprietary Information
Leveraging AM – NPI Hardware
Fuel Swirlers 7th set of HPT’s in 6 years
Substantial cost and lead time reduction Design refinement options Land-based Gas Turbine Engines
90 parts in (3) months Met testing timetable Eventually will be castings
GE Proprietary Information
Export Authorization, ECCN: 9E991, NLR
DMLM Design Advantage
LEAP Fuel Nozzle
GE Proprietary Information
DMLM Fuel Nozzle Design History Begin TAPS
Development
CoCr DMLM Material
Development
DMLM for
prototype testing
GEnx certifies
Traditional Mfg.
22 piece construc.
DMLM supply
chain acquisition
LEAP FETT
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
LEAP 1 piece
DMLM Nozzle
GE Proprietary Information
LEAP 56 Next Generation Fuel Nozzles 19 Fuel Nozzles in each engine
– 40K full production 20 pieces to 1
5x durability improvement
25% weight reduction
(compared to GEnx)
Fuel Nozzle is a very efficient heat exchanger
GE Proprietary Information
Exploring Optimized Structures
Optimized Result: 30% less weight
Original Re-designed (conceptual)
• Combine parts to eliminate weight
• Performance gains
• Maintenance reduction
• Optimal structure designs
GE Proprietary Information
45
EXPERIENCE ON EBM - TiAl
Advantages of the EBM process:
low level of internal defects, no typical casting
defects, therefore low scatter in material properties
homogeneous microstructure
very fine grain size, leading to good material properties, in particular fatigue
properties, and no need for grain refinement
no limitations in chemical composition
no residual stresses due to high process temperature
little waste material: powder can be recycled as the oxygen pick-up is very
low
GE Proprietary Information
AM Integration Within GE Corporation
Additional Considerations…
GE Proprietary Information
Export Authorization, ECCN: 9E991, NLR
Accelerating Adoption
Present 2014 2016 2018+
Process Variation
Validation Tools
Surface Finish
Growing Acceptance with Continuous Innovation
Accepted Industry Standards
Process Monitoring
Diversified Materials
Higher Capacity Machines
Application Specific Machines
Predictive Analysis Tool
Gradiated Materials
Accepted Best Practice
Process
Automation
GE Proprietary Information
Gaps and Challenges
•Rapid Qualification
& Materials Database
• IP: Rights & Tracking
•NDT / Internal Flaw detection
•Supply Chain:
Development & Protection
•Available Materials
•Technician Skill Level
General
Process Specific •Surface Finish
•Distortion
•Build Volume
•Throughput
•Process Monitoring and Control
GE Proprietary Information
Export Authorization, ECCN: 9E991, NLR
Supply Chain Shift?
From
To
GE Proprietary Information
Export Authorization, ECCN: 9E991, NLR
More Local?
Field Operation Substantial supply chain challenge in remote locations
Spare / Repair parts on-site?
Mobile Additive Center concept
GE Proprietary Information
Export Authorization, ECCN: 9E991, NLR
Parts Inventory
Local ability to grow parts?
Controls inventory
Balance inventory with needs/delivery
Flexibility for design changes (no order minimum)
GE Proprietary Information
Broad Trends
Challenging IP landscape
Further consolidation (all areas)
Increased adoption of technologies
Accelerating innovation
New business models
0
20
40
60
80
100
120
140
160
2012 2013 2014 2015 2016
Applications
IP
Alloys
GE Proprietary Information
Export Authorization, ECCN: 9E991, NLR
Creators & Pioneers
Early Adopters
Primary Majority
Secondary Majority
Holdouts
What Phase Are We In?
Technology Maturation and Acceptance Curves
GE Proprietary Information
~$10.5 Trillion
Global Mfg. Output:
Additive’s Potential::
~$2.2 Billion Professional Industrial Additive Market
~0.02% of total global Mfg. output
What if was 1%?...=$100B!
Imagination at work.
Thank You!