Additive Manufacturing For Industrial Applications

DNV-GL Technology Week 2018

10-16-2018

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Who We Are: Carpenter Technology’s Evolution

▪ Transitioned from a steel to specialty alloy focused company supported by 128+ years of

metallurgical expertise

▪ Today, we are a high performance materials and advanced process solutions provider for critical

end-use applications

▪ Metal technology capabilities for a wide range of next-generation products and manufacturing

techniques

▪ Evolving to next generation end-to-end additive manufacturing solutions provider

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History of innovation in powder and AM technology

History & Milestones: Powder and Additive Manufacturing

Titanium powder

Acquired 2017

1980’s-1990’s

Gas Atomized

Powder R&D

Additive Manufacturing

Technology Center

commissioned 2017

Metal component additive

manufacturing

Founded 2005

Ultrafine powder

Acquired 2008

CPP Sweden

Acquired 2000

CPP Bridgeville

Acquired 1997

Acquired 2018

40+ years in advanced powder technology

Over 3000 build cyclesMultiple flight qualifications

Built superalloy

gas atomizer

Athens, AL Announced

Emerging

Technology Center

Athens, AL

2019

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Overview

▪ Introduction to AM

▪ How Carpenter participates in AM

▪ What metals AM can do

▪ What metals AM cannot do

▪ Nickel 718 Material Design Case Study

▪ What fundamental problem are we trying to solve?

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Each approach suited to own applications and markets

Laser PBF EBM Binder jetting & DED

80% of machines

▪ Fine powder (~15-63µm)

▪ ~15 commercially available materials (Ti64, CoCrMo, 316L, 17-4PH, C300, 718, 625, etc

10% of machines

▪ Coarser powder (~45-105µm)

▪ ~3 commercially available materials (Ti64, 718, CoCrMo)

▪ Currently 1 OEM (GE)

Technologies Overview

~10% of machines

▪ MIM cut to fine powder for binderjetting

▪ Coarse powder for DED (~45-200µm)

▪ ~10 commercially available materialsReading AM Tech

Center & CalRAMCalRAM

Reading AMTC

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What AM Can Do

Elimination of Design Constraints One Seamless Part

Flexibility to manufacture parts that would not be possible or

economically feasible to produce using traditional manufacturing

AM allows the ability to produce one seamless part, which

historically would have required the assembly and welding of

multiple parts together

Reduced Cost of Complexity Mass Customization

AM technology enables users to produce complex parts at little or

no incremental cost versus simple parts

Because 3D printers do not require tooling or significant setup

costs, users are able to produce customized parts in a cost-

effective manner

Reduced Time to Market Cost Effective Production

AM enables digital designs to be printed, tested, evaluated, and

modified quickly

Repair and replacement parts

The upfront tooling and setup costs required in traditional

manufacturing are not required when using AM technologies

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However, it will have a material impact on future designs and manufacturability

Substitution or enhancement by AM

Landing gear forgings (maraging steel)

Engine shafts (Ni)

Flap tracks

(maraging)

Ducting & tubing (Ni)

Forged rings/discs

(Ni alloys)

Drill collars

(non-magnetic)

Fasteners

(Ni, steel, Ti)

Bearings (Ni)

Medical implants (CoCr, Ti)

Tooling:

dies & molds

High speed tooling

Electrical laminations

Unlikely to be impacted by AM, other

than indirectly (e.g., through tooling)1

Unlikely / distant Likely / already

1) Why? Large, simple shapes, critical parts requiring significant forging/upsetting, high volume components such as fasteners, and sheet form all unsuited to AM

AM does Not Replace Traditional Manufacturing…It Complements It

LWD Tools

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Production capacity to scale with customers’ growth

AM Powder and Wire Production

Alabama

State of the art

superalloy facility

West Virginia

High purity Ti alloy

powders

Rhode Island

Ultrafine (MIM)

powders

Pennsylvania

2x VIM and 1x air melt

atomizers

Sweden

Stainless & Tool

steels

High temperature

superalloys

Binder Jet alloys Tool steel

Stainless steel

Specialty gradesTitanium

Gamma TiAl

Titanium and Nickel wire used

in direct deposition

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Acquired Puris LLC (Titanium Powder) in March 2017

Bruceton Mills, West Virginia

Electrode Induction Melt Gas Atomization(EIGA)

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Each type of AM requires optimized raw material size and shape

Use of Different Particle Sizes

ISO/ASTM 52900:L-PBF = Laser Powder Bed Fusion; EB-PBF = Electron Beam Powder Bed Fusion; MIM = Metal Injection Molding

Deposition &

EB-PBF

“Mid Cut”

45-109 µm

L-PBF

“Fine”

15-45 µm

15-53 µm

Binder Jet / MIM

“Ultrafine”

0-22 µm

Fine wire

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Advancing Breadth of AM Materials Across All PlatformsProprietary process guidance for: Type Alloy EBeam-PBF Laser-PBF Binder Jet

Titanium

Ti-6-4 ✔ ✔Ti-6-2-4-2 ✔ ✔Gamma TiAl ✔C.P. Ti ✔

AluminumAlSi10Mg ✔AM205 ✔

Nickel

718 ✔ In development

625 ✔ In development

HX ✔ In development

H230 In development

Cobalt

CoCrMo ✔ ✔Micro-Melt 6 In development In development

CCW+ In development In development

Steels

M300/C300 (1.2709) ✔ ✔ ✔Custom® 465 In development

17Cr-4Ni ✔316L ✔420 In development In development

H13 Tool Steel In development In development

Copper C18200 (CuCr) ✔*Additional alloys being prioritized throughstrategic partnerships

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Reading AM Technology Center – Alloy & Process Support

Expertise to support end-to-end development needs

Alloy development

& commercialization

Fundamental material-

process interactions

Process windows for

novel alloys

Heat Treat & HIP cycle

innovation

Other CapabilitiesAdditive Equipment

▪ SLM 125 (L-PBF)

▪ SLM 280 HL – Dual Lasers (L-PBF)

▪ 3D Systems ProX320 (L-PBF)

▪ Trumpf TruPrint 1000 (L-PBF)

▪ ExOne MFlex (Binder Jet)

▪ ExOne Innovent (Binder Jet)

▪ Optomec LENS MR7 (Direct Energy Deposition)

▪ R&D vacuum melt atomization

▪ Powder characterization

▪ Powder handling protocols

▪ Metallurgical testing

▪ Microstructure analysis

▪ Vacuum sintering

▪ Hot Isostatic Press (HIP)

Alloy Development

▪ Global, world-class R&D capabilities

▪ Broad, diverse network including national labs, industrial research labs, & universities

▪ Focus on partnering with customers to develop alloys for critical applications

▪ Multiple R&D 100 Awards

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Respected industry leader for AM part production in AS&D and Energy applications

CalRAM Inc. -- Full Solution Metal AM Production Over 3000 build cycles completed since 2005

Flight qualified with multiple OEMs

B-Basis allowables developed for Ti-6-4

Design & Engineering Additive ProductionIn house post

processing

Metrology

inspection

AccreditationsCapabilities

▪ 25,000 sqft manufacturing space

▪ (3) ARCAM A2X (ePBF)

▪ (1) ARCAM S12 - Modified (ePBF)

▪ (1) SLM 280 HL - Dual Lasers (LPBF)

▪ Metallurgical expertise and focus

▪ Design change management protocol (IP)

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The early stage research solutions can be scaled up for production through our ETC

Emerging Technology Center for Low Rate Initial Production

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Carpenter approaching challenges from the materials perspective

Metallurgy Metrology Application Business Case

▪ Control of defects e.g. voids

▪ Susceptibility to microcracking

▪ Alloys not designed for AM

▪ Anisotropic properties

▪ Unknown acceptable ranges of process variation

▪ Dimensional accuracy

▪ Support & thermal management

▪ Feature-based melt parameters

▪ Streamlined post-processing

Each New Material & Application Faces Challenges

▪ Yield & productivity

▪ Tradeoffs vs. casting

▪ Product lifecycle costs

▪ Insource vs. outsource?

▪ Qualification time & cost

▪ CapEx to scale

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Carefully manage powder, part orientation, and machine processing conditions

Poor control of process & powder Good control of process & powder

Process defect

Powder defects

Print Parameters: Need for Controlled Process

What changed?

Powder refinement – for example, minimized gas entrapment

Parameter optimization – more consistent welding

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Leveraging Deep Knowledge and Capital Assets for Tailored Alloy Solutions

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Process Flow Chart – 718 Specimens

T1: DMLM

Processed

specimen

T5:Sol An/Age at 1800 F (980 C)

for 1 hr, Cool to 1330 F (720 C)

hold 8hr, cool to 1150 F (620 C)

hold 8hr cool to RT

T6: Met Porosity

T6: Met

Specimens

T4:HIP at 2175 F,

(1191C), 15 ksi (100

Mpa), 4hr

T2: EDM from

Plate

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(Sol Anl/ Age HT) 718 microstructures

Transverse Longitudinal

(as built) 718 microstructures

The delta phase is an Ni3Nb

intermetallic

As-built vs heat Treated Microstructure

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(HIP/ Sol Anl/Age HT) 718 microstructures

Transverse Longitudinal(Sol Anl/Age HT) 718 microstructures

Grain Size: non-equiaxed ~4.

The delta phase is an Ni3Nb

intermetallic

Grain Size:

wide range, 2-7

avg. 5.

Effect of HIP- Grain Size

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(HIP/ Sol An/ Age HT) 718 microstructures

Vertical Horizontal

(Sol An/ Age HT) 718 microstructuresEffect of HIP Porosity

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Mean porosity 0.02 %

Density 99.98%

Final Parameter Selection for Alloy 718

40 μm Layers, SE – 67.5 J/mm3

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CVN Specimens Tensile Specimens

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As BuiltHorz Impact

Energy

(ft-lbs)

Vert Impact

Energy

(ft-lbs)

HC-1 75 C-4 77

HR-1 80 FR-1 75

HL-1 77 FL-1 75

HF-1 77 BL-1 73

HB-1 76 BR-1 73

Mean 77 Mean 74.6

sd 1.67 sd 1.5

Horz Impact

Energy

(ft-lbs)

Vert Impact

Energy

(ft-lbs)

B3 11.5 BL-3 15.4

F3 13 BR-3 14.4

L3 12.6 FL-3 15.8

R3 13.5 FR-3 16.8

C6 12.2 C-3 14.5

Mean 12.56 Mean 15.38

sd 0.76 sd 0.99

(Sol An/Age HT) (HIP/Sol An/Age HT) Horz Impact

Energy

(ft-lbs)

Vert Impact

Energy

(ft-lbs)

B2 17.5 BL2 20.3

C2 17.1 BR2 23

F2 16.7 FL2 22.6

L2 17.1 FR2 20.6

R2 18 C5 21.1

Mean 17.28 Mean 21.52

sd 0.49 sd 1.21

Charpy Impact Test Results

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0

50

100

150

200

250 718 LPBF Properties

As Built V

AS Built H

Sol HT V

Sol HT H

Hip/Sol HT V

Hip/Sol HT H

EOS As built 718: H; ys – 113 ksi, uts-154 ksi, EL% - 27, V – ys-92 ksi, uts-142 ksi, EL%-31

F3055-14a as built: H; ys – 92.1 ksi, uts-142 ksi, EL% - 27, V – ys-87 ksi, uts-133 ksi, EL%-27

YS (ksi) UTS (ksi) EL (%) RA (%)

Tensile Testing Results

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Leveraging Deep Knowledge and Capital Assets for Tailored Alloy Solutions

Translating powder chemistry and printing parameters into optimal microstructures and properties.

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Examples of AM Projects:

▪ Inflow control devices

▪ Flow manifolds

▪ Valve bodies & inserts

▪ Erosion control

▪ Filters

▪ Turbochargers/turbines

▪ Heat shrouds

▪ Heat exchangers

▪ Fuel injectors

▪ Fuel nozzles

▪ Instrumentation housings

▪ Tooling

▪ Jigs & fixtures

What Fundamental Industrial Problems Are We Solving?

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Questions?