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Advances in Arc and Hybrid Welding, and AM of Titanium AlloysITA Conf 2010, Orlando
Ian D. Harris, Ph. D.Technology Leader, Arc WeldingTechnical Director, AMC
614 688 [email protected]
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Outline
Welding Titanium- Novel arc welding- Laser and Hybrid Laser Arc Welding (HLAW)
Additive Manufacturing (AM)- Arc Welding
Additive Manufacturing Consortium (AMC)- Need for Collaboration
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Roadmap - High Consequence Arc Welding
Heavy fabrication and military applicationsNuclear fabricationB&PVAero and Space applications Using micro-TIG at 0.5 lb/hr through orbital GTAW to out-of-position NG Tandem GMAW at 35 lbs and /hrHLAW for X80, and X100 linepipe, HSLA 100 steels for carrier and submarine hulls, low-alloy steels for B&PV applications, etc.Alloys of titanium, nickel, aluminum, copper, stainless steels (all grades from austenitic to superduplex)
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Precision GMAWBenefits:
Reduced heat-input, residual stress, distortionPrecise deposit shape controlFiller metal coaxial with the torch- Less complex mechanism - Easier to automate
Cost savings (compared to dabber GTAW or laser)- Lower capital equipment cost- Higher productivity
Need:Assess feasibility for high-alloy build-ups
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Precision GMAW
1.5 mm Ti6-41.5 mm Ti6-4
Nickel alloy clad on steel< 0.5% dilution achievable
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Hybrid Arc Metal Transfer
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Precision-GMAW Build-Up
1.5mm
Stainless steel edge build-up• 18 ipm Travel speed • Heat-input < 1 kJ/in
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Low Power GMAW-P of Ti
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Laser Stabilized Arc Welding
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Yb – Fiber Laser Welding of Ti 6-4
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Laser Welding of Thin Sheet Ti 6-4
Robotic Yb-Fiber Laser welded flat and formed sheet products in the thickness range of .032” -.125”Dual fillet welds with wire addedDistortion related to low welding speed and dual fillet weld rather than single pass ‘skid’ weld
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Hybrid Laser Arc (HLAW)
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Benefits of Hybrid Laser Arc
High Energy Density of Laser- Deep Penetration- High Travel Speed
Filler Wire Addition of GMAW- Gap Tolerance- Alloying Elements
Suitable for steels, stainless steels and nickel-based alloys
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Enabling Tech - Yb-Fiber Laser
High efficiency; >25% (vs. 3 to 6%)Long potential diode life; > 25,000 hoursCompletely fiber generated and delivered
Very scalable; 20 kW systems exist (70 kW sold)Robust systemNear Perfect Beam
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Prototype P450 Hybrid Head
Upgraded TPS3200 to TPS 5000 for 500 A GMAW capability with higher WFS and deposition rate for increased weld throatIncreased travel speed to 120 in/min (3 m/min) by gearing15-kW laser power currently availableEffective throat up ½-in (13-mm) single pass
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Legend
• Friction Stir Welds • Hybrid Laser Welds• GMAW-P Welds
Ti 6-4 Demo Hull Fabrication
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Lower Glacis to Front Glacis Corner Joints (LBW and HLAW)
Root pass (LBW only)- 20-IPM Travel speed- 4-kW Laser power
Cap pass (HLAW)- 15-IPM Travel speed- 215-IPM Wire feed speed
• 0.035-in wire- 2-kW Laser power
Tooling Model Tooling Assembly with welded part
Ti 6-4 corner joint with multi-step path geometry (0.5-in to 0.25 and 0.5-in)
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Bulkhead to Front Glacis/Outer Sidewall/Sponson/Inner Sidewall (GMAW-P)Ti 6-4 fillet joint with multi-step path geometry (0.5-in to 0.25 and 0.5-in)Fillet weld parameters:- 20-IPM Travel speed- 400-IPM Wire feed speed
• 0.045-in wire
Tooling Model Final Assembly
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AM – Progressive Layers
Build in layers, Stress relieve/PWHT, Machine
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AM Processes for Metals
EBW freeform fabrication - EB(FFF)Laser powder and wire for FFFLAM, LENS, DMLS, from companies such as Arcam, EOS, POM – powder and wire based laser and EB metals AM in confined envelope Arc processes – GTAW-HW, GMAW-P, PTA (wire and powder) based on commercially available equipment for FFFVHP UAM – very high power ultrasonic AM
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Example Metals AM Processes
Concept Laser DCM®
EOS DMLS®
MTT SLM®
Phenix Systems
Optomec LENS®
MTS Aeromet LAM(No longer in
business).
Sciaky EBFFF
Arcam EBM®
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Deposition Rate vs Resolution
Courtesy Boeing
Decreased Resolution
Incr
ease
d D
epos
ition
Rat
e
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Additive Manufacturing -Feature Size CapabilityFrom single beads stacked upon each other (bottom)To large features at high deposition rates (top)Mitigated by balance of net-shape, metallurgical requirements, mechanical properties (tensile, fatigue, etc)
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Arc-Based Additive ManufacturingDemonstrated arc-based processes for Titanium additive manufacturing- GMAW-P- RWF-GMAW- PAW (Cold Wire)- PTA (Powder)- GTAW (Hot Wire) GMAW-P
PAW (Cold Wire)GTAW (Hot Wire) RWF-GMAW
PTA (Powder)
Proprietary to Lockheed Martin Copyright 2009
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Titanium Additive Manufacturing
Process Productivity Distortion
GMAW-P Medium Medium
RWF-GMAW Medium Low
PAW (Cold Wire) Low Medium
PTA (Powder) Very Low Low
GTAW (Hot Wire) High High
Arc-based processes are generally less capital intensive and more productive than many other additive manufacturing processes
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Example Applications
EB FFF and DMLS parts for aerospace components
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Example Applications
Land vehicles- OEM- Repair
Power generation and nuclear
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AM Evaluation Stages
Evaluation Stages – AMS-4999 Revision- 1 Initial Screening- 2 Process/Source Approval- 3 Deposition Parameter Approval- 4 Approval on Non-Critical Flight Hardware- 5 Approval of Critical Flight Hardware
MMPDS data generationNon-flight Hardware Qualification stops at Stage 4
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Collaboration Needed
Wide Range of Processes Necessitates InvestigatingEach Process in Detail – this is very expensive and requires
collaboration
Initial Acceptance Values Based on LAM Process FormLower Bound for Tensile Properties, Typical forFatigue Crack Initiation
Stage 2 Evaluation of Several Processes Necessary toFully Validate Use of LAM Values for All Approvals ofProposed AMS 4999 Revision
Stage 2 Evaluation of 6 to 7 Processes Needed forCertainty of Generating MMPDS Allowables
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The Answer: AMC
The Additive Manufacturing Consortium (AMC) was founded to provide a U.S. AM forum and is already attracting international interestConsortium of industry, government, and research organizationsMission: Advance the manufacturing readiness of metal AM technologies to benefit consortium members
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Time to deployment
Man
ufac
turin
g R
eadi
ness
University & Federal Labs
Manufacturers & Suppliers
Additive Manufacturing
Consortium
MRL 3-7Significant commercial impacts in 2-5 years
MRL 8-10Incremental improvements and implementationShort time horizon
MRL <3High-risk basic research and educationLong time horizon
Advancing Manufacturing Readiness
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AMC StructureEncompass a wide spectrum of manufacturersInclude technology and material suppliersEngage a technology network of research partners; “National Test-Bed Center” Creates a non-competitive environment for industry to share experience and best-practicesLeverages public and private funding sourcesDistinct from university-led centers which often focus on education and basic-research
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Conclusions
Continued development of arc and hybrid processes for welding titanium alloys for commercial and military applicationsHLAW offers potential for 5/8-in (15 mm) single pass with a SECB joint or 5/8-in root face using a 15kW laserAMC offers collaboration for development of metals AM using Laser, EB, arc and other processes