Titanium additive manufacturing – a novel game changing technology

TITANIUM 2014 Conference September 21-24, 2014 Francisco Vega, VP Sales & Marketing

Slide 1

September 21-24, 2014 • Hilton Chicago, Chicago, Illinois, USA

Introduction

Private & Confidential Slide 2

» Norsk Titanium has developed an innovative additive manufacturing technology based on wire feedstock as raw material and utilizing plasma arc as a heat source.

» The process has been developed for deposition of titanium and titanium alloys, hereunder the most common used alloy for aerospace applications, Ti6Al4V.

» The process lends itself to production of parts with geometries and properties of industrial interest, such as structural aerospace components.

Introduction (suite)

Private & Confidential Slide 3

» Production of aerospace parts by conventional technologies requires about 5 times the material amount in the final part, and individual parts may have “buy to fly” values of 10 or more. Additive manufacturing can reduce the “buy to fly” ratio significantly, typically to 1.5 or better.

» Reduced lead time and flexibility in design as additional benefits. The Norsk Titanium process is presently pending qualification for the commercial aerospace market.

» This presentation will give an introduction to the process and material properties achieved.

About NTi

Private & Confidential

» NTi is a titanium component producer based in Norway

» NTi has developed a novel game changing technology (3D printing) to produce complex Titanium components with unsurpassed quality

» This technology uses the principle of Direct Metal Deposition (DMD) technology, with a patented plasma arc based 3D printing production method

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Chronology of milestones

» 2007 NTi is established by Scatec AS » 2008 First prototype cell (POA) » 2009 Second production cell (POB) » 2009 Cooperation agreement with Spirit

Aerosystems » 2011 Norsok qualification » 2012 TRL3 with Airbus » 2012 Next generation cell P01 » 2012 TRL6 with Spirit Aerosystems » 2014 Completion of production of

allowables material » 2015 TRL8 (FAA) qualification expected

in 12 months » 2015 TRL8 (EASA) qualification expected

within 2015

NTi: Introducing industrial scale 3D printing

NTi is close to commercial Aerospace qualification

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Actual system «flight proven» through successful mission operations

Actual system completed and «flight qualified» through test and demonstration (ground or flight)

System prototype demonstration in a space environment

System/subsystem model or prototype demonstration in a relevant environment (ground or slight)

Component and/or breadboard validation in relevant environment

Component and/or breadboard validation in laboratory environment

Analytical and experimental critical function and/or characteristic proof-of-concept

Technology concept and/or application formulated

Basic principles observed and reported TRL 1

TRL 2

TRL 3

TRL 4

TRL 5

TRL 6

TRL 7

TRL 8

TRL 9

Technology Demonstration

Technology Development

Research to Prove Feasibility

Basic Technology research

Large scale consistency test/allowables plan

Component test/commercial

launch/operations

TRL: Technology Readiness Level

Titanium 3D printing still not widely adopted within aerospace

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3D printing is referred to as the 3rd industrial revolution

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1st 3rd 2nd

Late 18th century Early 20th century Now

United Kingdom United States of America Globally

Mechanization of textile industry Mass production (Ford)

Mass customization through digitalization of manufacturing

Multiple Titanium manufacturing processes available

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Conventional part manufacturing processes

Additive Manufacturing/ 3D Printing processes

Milled plate • Mill annealed • Beta annealed

Powder based • Laser

• Powder melting • Powder sintering (SLS) • Powder blowing

• Electron beam • Powder melting • Powder sintering (EBS)

Wire based • Electron beam

• Electron beam free form fabric. (EBFFF) • Laser • Arc

• Plasma arc direct metal deposition (DMD)

Forgings • Forged block • Die forgings

Extrusions

Castings • Precision castings ++ • Hot Isostatic Pressing (HIP) castings

Sheet metal based • Sheet metal ultrasonic consolidation

Conventional forming

In commercial aerospace, Ti AM (powder based) mainly replacing castings

Many AM initiatives related to engines...

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• GE Aviation JV with Snecma to manufacture >30000 fuel nozzles annually for its LEAP engine starting with 2016.

• Pratt& Whitney to make the PW1500G engine (for Bombardier Cseries) will contain 24 AM metal parts from 2015.

• Rolls-Royce is gearing up to use 3D printing technology to produce components for its jet engines, as a means of speeding up production and making more lightweight parts.

…but, no viable alternatives on aerostructures - until NOW!

Titanium 3D print in commercial aerospace » Not yet adapted, mainly

future applications » Lower quality

requirements to replace casted parts, mainly engine

» Represents a relatively small share of the Titanium fly weight

» No solution for structural parts implemented yet

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3D printing of titanium components A technology that will transform the titanium market

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Private & Confidential Slide 12

A

B

NTi technology » Production of Ti Wire and Production of Components

Pilot Cell 0A (Dismantled)

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» Started production in December 2008

» Produced prototype products: - Oil & gas industry (flanges & el-pods) - Aerospace industry (test samples) - Industry (ball valves) - Desalination (valves – energy recovery)

» Market focus: - Oil and gas (exploration), and general

industry - Emerging markets - Prototype products for emerging

markets

» Capability of manufacturing a part of up to a gross mass of 450 kg, and a size of 120 cm x 80 cm, Ø = 80 cm

» Gross deposition rate of 0.4 Kg/hr

Seismic O & G exploration

Development Cell 0B

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» Started production in September 2009

» Produced prototype products: - Oil & gas (flanges) - Defense (rocket engine part) - Aerospace hybrid component - TRL 4, and 6 aerospace samples

» Market focus - Aerospace - Oil and gas (production) / industry - Defense

» Capability of manufacturing a part with a gross mass of up to 180 kg, and a size of 90 cm x 50 cm, Ø = 100 cm

» Gross deposition rate of 3-5 Kg/hr

Production Cell P01

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» Started production in February 2012

» Produced prototype products: - Defense (titanium armored plate

samples) - Aerospace aerostructure component - TRL 6, and 8 aerospace samples

» Market focus - Aerospace complex components

» Capability of manufacturing a part with a gross mass of up to 200 kg, 180 cm x 120 cm x 120cm, Ø = 120 cm

» Wall angle upto 45°

» Gross deposition rate of 5-10 Kg/hr

Aerostructure component

It all starts with a CAD design of the component

NTi technology and production process

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Deposition program is generated using the

CAD data

Transferred to the DMD production unit

Plasma arc welding of titanium wire directly on

substrate

Manufacturing a near net shape component

Minimum machining to obtain finished shape

Homogenous microstructure across

layered material

Reduced waste compared to traditional

production methods

Pre-form to finished component

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Manufacturing of Titanium Components Titanium sponge Melting companies Forging Milling companies Rough machining Finish

mach.

Product Sponge Melting Bloom 80-90% Forging Rolling Mill product

Mill product

Pre-form

Mill/ Pre-form

Titanium sponge NTi Machining

Wire production/supplier Final product DMD production

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Source: Titanium Center of Competence and NTi

Ultra high Forged parts for

commercial aero

Casted quality

Forged parts for military applications

(Ti64 challenges)

Casted quality

5 - 10 kg/hour (Net production rate

~15,000kg/year)

5 - 10 kg/hour

5 - 10 kg/hour

Production rate

~200 kg/year

Wire + plasma arc (Inert atmosphere)

Blown powder based + laser

Wire + electron beam based

(Vacuum)

Powder bed based + laser or el beam

(vacuum or inert atmosphere)

NTi vs other 3D metal printing technologies Technology Deposition rate Quality Ideally suited for…

Both small and large components

Both small and large components

Both small and large components

Small high value components with highly complex

internal structures

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Norsk Titanium (NTi)

Microstructure

» Controlled microstructure through thermal management, atmosphere control, and automation of other production parameters

» Able to achieve forged requirements consistently.

As deposited microstructure – lamellar/basketweave α/β structure

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Meets the highest material standards Yield strength Tensile strength Production type

>910 >835

896 827 Forging

(Standard: AMS 4928, Rev. “S”)*

893 827 Plate - Mill annealed (Standard: AMS 4911, Rev.

“M”)*

841 745 Plate - Beta annealed

(Standard: AMS 4905, Rev. “D”)*

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862 793 Casted

(Standard: AMS T-81915, Rev. “T-81915”)*

Design defect factor

N/A

N/A

N/A

N/A

Applicable due to pores and voids

* SAE International Aerospace Material Specifications (AMS)

NTi value proposition

Cost efficiency

Shorter lead times

Flexibility & ability to customize

Quality & reliability

Green technology

» Reduced production cost » Reduced price volatility due to improved near-net-shape

» Conventional technologies: 4-12 months for aerospace & 4-6 months for defense

» Flexibility in design changes, time & form, reduces risk for obsolete design

» Attractive for prototyping

» Detailed production database » Accreditations for aerospace (Spirit TRL6*, going for TRL8*) and oil &

gas (NORSOK)

» Reduced waste & energy consumption due to the improved near-net-shape

Private & Confidential

* Technology Readiness Level

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Summary

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Titanium market under pressure, high demand and concentrated supply chain

Titanium 3D printing still not widely adopted within aerospace

Norsk Titanium breaking aerospace misconceptions by offering a new solution

A shift in the demand for advanced titanium components

Market growth is driven by lighter and more fuel efficient aircrafts

Concentrated supply chain results in long lead times

3D printing believed to be the 3rd industrial revolution

Ti 3D print mainly used to replace castings (engine) in commercial aerospace

No solution for 3D printed To structural parts implemented yet

Large scale additive manufacturing of Ti parts (drop-in replacement) for medium to large parts

High material quality and TRL8 maturity level

Competitive cost, price and high delivery flexibility

Norsk Titanium (NTi) Eggemoen Aviation & Technology Park Flyplassveien 21 | 3514 Hønefoss | Norway Phone: +47 97 42 22 00 Web: www.norsktitanium.no E-mail: post@norsktitanium.no

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