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Additive Manufacturing Material Implementation at GEGE Additive10 August, 2017

Confidential. Not to be copied, distributed, or reproduced without prior approval.

What is Additive Manufacturing (a.k.a. 3D Printing)

• 3D printing or additive manufacturing (AM)

• is any of various processes for making a three-dimensional object of almost any shape from a 3D model or other electronic data source primarily through additive processes in which successive layers of material are laid down under computer control.

• - Wikipedia

Subtractive(Traditional)

Additivew

aste

Successive layers of material are laid down

133

DMLM (Direct Metal Laser Melting) Basic Process Map

3D CAD Model

AM ProcessThermal

Processing

Post Processing/ Inspection

Final Part

Prep for Process

134

GE’s advancement in additive … so far

2010 2011 2012 2013 2014 2015 2016 2017

Tech

nolo

gyIn

fras

truc

ture

Formation of GE Aviation additive team

1st LEAP Fuel Nozzle

Acquisition of Morris

Technologies

1st Heat Exchanger

GE90 engineT25 Sensor

FAA Certified

LEAP Fuel Nozzle FAA Certified

GE Aviation Additive Technology Center

(ATC) opens

GE’s Center for Additive Technology Advancement

(CATA) opens

Acquisition ofConcept Laser GmbH (75%)

Arcam AB (76%)

A-CT7 Engine Bigger Parts

Rotating Parts

Bigger Systems

Multi Modalities

GE Additive Expansion

Customer Experience Centers

Advanced Turboprop Prelim design

Power F-Class Flex Tip Oil & Gas

Nova LT Swirler

16+ years of Additive Science

Capabilities of full production35,000 – 40,000 per year

PARTS

DURABLEMORE

WEIGHT

It started with one part …

25%

20 1

5xREDUCTION

LEAP is a trademark of CFM International, a 50/50 JV between GE and Safran Aircraft Engines© 2017 General Electric Company - All rights reserved

GE Proprietary Information

GE Confidential Information

Additive value proposition – LEAP fuel nozzle actuals

0%

100%

Inventory Life Cycle Cost Mfg Cost Part Weight

Traditional TAPS Fuel Nozzle LEAP DMLM Fuel Nozzle

Advanced turboprop engine (ATP)

PARTS

WEIGHT REDUCTION

Combustor test schedule reduced from 12 months to 6 months

LOWER MISSIONFUEL BURN

© 2017 General Electric Company - All rights reserved


Modalities and Materials


Process Form Heat Source Speed Precis Size

Pow

der B

ed DMLMDirect Metal Laser Melting

Powder Bed Laser

EBM Electron Beam Melting

Powder Bed Electron Beam

Depo

sitio

n

LPF Laser Powder Forming

Powder Deposition Laser

Cold Spray Powder Deposition Momentum

EBFF Electron Beam Free Form

Wire Electron Beam

Hot Wire Wire TIG/ Laser

Cons

olid

atio

n MIM/SNS HIPMetal Injection Molding

Binder Injection Consolidation

Binder Jet Binder Jet Consolidation

Available metal additive optionsL

L

TIG/L

EB

EB

Concept Laser and ARCAM Products

A2

Xline

Mline

M2

Mlab

Q20Q10


Typical DMLM to EBM comparison

Direct Metal Laser Melting Electron Beam Melting

Energy Source 100-1000 WFiber Laser

3000 W Electron Beam

Scanning Method Optical Mirrors Magnetic DeflectionBuild Layers 20 to 50 µm 50 to 70 µmAccuracy 50 µm 200 µmBuild Rate 13 cm3hr-1 55 cm3hr-1

Surface Finish 100-300 µ-in 800-1000 µ-inResidual Stress High Low


Currently available materialsStandard Alloys Available:

• Cobalt Chromium• Inconel 718, 625• Titanium 6AlV4 ELI, CP Ti Grade 2• Aluminum (AlSi10Mg, AlSi12)• Stainless 316L(1.4404), 17-4PH • Maraging Steel MS-1 (1.2709)• Bronze

Many more materials currently in development

Inco 718

Inco 625

SS 316L

17-4 PH

SS 15-5 MS-1

Cu AlSi10Mg

6061 T6 CoCr HastX

Ti6242 Ti 64

W

TiAl

A205

F357

HS188

Rene 80


Material properties drive applications

140

150

160

170

180

190

200

210

DMLS - V DMLS - H Wrought Low Wrought High

YS (ksi) UTS (ksi)

AMS

AMS

AMS

AMS

0.0

10.0

20.0

30.0

40.0

50.0

DMLS - V DMLS - H Wrought Low WroughtHigh

Elongation (%) Hardness (HRC)

DMLM - V DMLM - H

DMLM - V DMLM - H



Qualification & Inspection


•Safetyis priority #

146

Identify

• Additive opportunities based on value• Durability, fuel burn, emissions, weight, cost, new and innovative functions

Mature• Machine, material, and process development• Process including machining / finishing, process monitoring, and inspection

Design• To established additive design practices and lessons learned• Taking full advantage of geometrical freedom and material enhancements

Qualify• Establish machine, material, process, and design requirements• Demonstrate all requirements are met or exceeded; lock processes

Validate

• To performance level component, system, and engine requirements• Coupling advanced analytics and testing

Certify• Component level testing as required (14 CFR Part 33 Section 33.91)• Engine level certification (14 CFR Part 33 & 34)

Additive Component Roadmap

Additive Materials Development Process

Concept

Feasibility

Development

Maturation

Process Content• Microstructural evaluation & heat treatment development• Process optimization / producibility• Mechanical properties & design curves / allowables• Environmental evaluation (fluids, corrodants, temperature/time, etc…)• Effects of subsequent processing / operation

Deliverables• Material understanding & use guidelines• Processing & robustness • Specifications• Physical & mechanical properties• Environmental evaluation• Component suitability

Mature


148

Powder Spec• Powder Source• Powder Size• Powder Composition• Powder Reuse Procedures

Laser Param• Spot Size• Laser Power• Laser Travel Speed• Laser Dwell Time

Therm Proc• HIP Cycle Parameters• Heat Treat/Solution Atmos• Braze HT Parameters• Solution Temperature

Recoat Param• Layer Thickness• Recoater Arm Material • Recoater Arm Design

Build Cham• Build Atmosphere• Purge Gas• Airflow• Preheat Temp• Interpass Temp

Hatch Strategy• Contour Pass • Sky Writing• Line Spacing or Boundary Overlap

Calib & Maint• Preventative Maintenance• Pre-build Calibration• Factory Environ Controls

Post Processing• Mechanical Finishing• Thermal Exposure

Cycles to Failure

Stre

ss C

apab

ility

Contour

Hatch

Laser Parameters

Explicit Controls on Machine, Material, and Process(Examples shown, not an all inclusive list)

Qualify


149

Qualification

Machine Material Process Part

Inspection

Non-Destructive

CT/VCT/CMM

Dimensional Defect Recognition

Functional Checks

Fuel FlowAirflowOther

Proof PressureUltimate

Test

Destructive

Part

Cut-Ups

Specimen

Grain SizePorosity Surface Finish

On-going Material Testing

Inspection and Quality Touch PointsValidate


150

In-situ Inspection, Modeling, and AnalyticsValidate


MeltpoolProcess

Monitoring

Analytics

Computational Materials

Engineering

Faster• Material Development• Process Qualification• Part Certification

d

151


Specifications Industry Groups

Supporting Industry Initiatives

152

Supply chain shift in progress


PRIMARY AND SECONDARY SCHOOLS (ages 8-16)

• $8 million for metal additive manufacturing equipment

• Focus on additive learning efforts

Apply at www.geadditive.com

Investing in a limitless future

• $2 million for 3D-printing equipment and curriculum

• Focus on STEM/STEAM programs

COLLEGES AND UNIVERSITIES (2- and 4-Year)

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