Additive Manufacturing for Space Applications: On Earth, On Orbit - PowerPoint PPT Presentation

Additive Manufacturing for Space Applications: On Earth, On Orbit and On Planet Andrew Norman A.D. Brandão, J. Gumpinger, B. Bonvoisin, A. Makaya, L. Pambaguian, T. Rohr, T. Ghidini European Space Agency, Materials and Processes Section Noordwijk, The Netherlands Engineering Integrity Society, MTC, 18 June 2019 ESA UNCLASSIFIED - For Official Use

Outline  Introduction to the European Space Agency  Why Additive Manufacturing for Space Applications  Manufacturing on Earth (The ESA Journey)  End-to-End Manufacturing Process  Additive manufacturing on orbit and on planet  Conclusions ESA UNCLASSIFIED - For Official Use Andrew Norman | 18/ 06/ 2019 Ana Brandao | 09/ 05/ 2018 | Slide 2

European Space Agency Today  Over 50 years of experience  22 Member States  Eight sites/ facilities in Europe, about 2300 staff  5.6 billion Euro budget (2018)  ESA is a procurement agency  Over 80 satellites designed, tested and operated in flight February 2018 ESA UNCLASSIFIED - For Official Use Andrew Norman | 18/ 06/ 2019 Ana Brandao | 09/ 05/ 2018 | Slide 3

ESA Locations www.esa.int Salmijaervi (Kiruna) Moscow Brussels Washington ESTEC (Noordwijk) Maspalomas ECSAT (Harwell) Houston EAC (Cologne) Santa Maria ESOC (Darmstadt) ESA HQ (Paris) Kourou Oberpfaffenhofen Toulouse New Norcia Perth Malargüe ESA sites Redu Offices ESA Ground Station + Offices ESA Ground Station ESA sites + ESA Ground Station ESA UNCLASSIFIED - For Official Use Andrew Norman | 18/ 06/ 2019 Ana Brandao | 09/ 05/ 2018 | Slide 4

European Space Research and Technology Centre (ESTEC)  Materials support to the missions  Run technology programmes  Testing / Evaluation Facilities  State-of-the-art laboratories  Equipment dedicated to space  Access to external test houses  Materials level  Component level  Spacecraft / Satellite level ESA UNCLASSIFIED - For Official Use Andrew Norman | 18/ 06/ 2019 Ana Brandao | 09/ 05/ 2018 | Slide 5

Materials, Structures and Mechanisms Materials and Processes/ Failure I nvestigation Vibro-Acoustic Environm ent Prediction/ Full Scale Testing Support Launcher Coupled-Multibody Analysis Detailed Stress Analysis Flight Acceptance/ Operations Early Design Phases Design for Dem ise ESA UNCLASSIFIED - For Official Use Andrew Norman | 18/ 06/ 2019 Ana Brandao | 09/ 05/ 2018 | Slide 6

Surviving in Space Thermal Environment / Vacuum Ground Storage / Launch Phase Telecom ~ 75,000 thermal cycles + 150˚ C -150˚ C Stress corrosion cracking CTE Mismatch Red plague corrosion Expulsion of volatiles (Cd / Zn) Vibration and Shock Cold Welding Zero Gravity Outgassing of volatiles Radiation / Charged Particles Space Debris / Demisability e Ultraviolet Rays High Energy Electrons Dust, Micrometeoroids Asteroids and Comets o Solar Protons Atomic Oxygen Space Junk Controlled Break-up / Demisable ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 7

Why adopt Additive Manufacturing for Space Applications ? ESA UNCLASSIFIED - For Official Use Ana Brandao | 09/ 05/ 2018 | Slide 8

Why Additive Manufacturing for Space hardware? Challenges for Space Materials and Processes: o   Low Mass Small Geometries   Small Production Series Very High Performances   Very High Reliability Challenging Material Procurement W hy Additive Manufacturing ? o  ALM addresses majority of above challenges  Applied to m any m aterials = > metals, polymers, composites, ceramics  Dim ensions : few micrometers to meters  Significant gains in perform ances  Environm entally friendly ESA UNCLASSIFIED - For Official Use Andrew Norman | 18/ 06/ 2019 Ana Brandao | 09/ 05/ 2018 | Slide 9

ESA Approach to Additive Manufacturing  Funded a number of activities across Europe  Fundamental Studies  Manufacture of Demonstrator Parts  End-to-end process (including qualification and standardization) Simple part reproduction Rethinking Process and materials selection Designing for Additive Manufacturing ESA UNCLASSIFIED - For Official Use Andrew Norman | 18/ 06/ 2019 Ana Brandao | 09/ 05/ 2018 | Slide 10

How it all started at ESA Simple reproduction Re-thinking Starting to Design Designing for AM Designing for AM Materials Selection (topology / properties) of existing parts for AM (Alloy design)  Failure in a Water On/ Off Valve on the ISS  Unit was returned to ESTEC for root cause analysis  Complex design  Thick and thin wall  Welded parts Would it be possible to manufacture the part as a single piece using the new technology of 3D printing ?? ESA UNCLASSIFIED - For Official Use Andrew Norman | 18/ 06/ 2019 Ana Brandao | 09/ 05/ 2018 | Slide 11

How it all started at ESA Simple reproduction Re-thinking Starting to Design Designing for AM Designing for AM Materials Selection (topology / properties) of existing parts for AM (Alloy design)  Simple reproduction of the same part  substituted stainless steel by titanium  Ti6Al4V powder available at manufacturer  40% mass benefits As built part  Part count reduction to 1 ESA UNCLASSIFIED - For Official Use Andrew Norman | 18/ 06/ 2019 Ana Brandao | 09/ 05/ 2018 | Slide 12

ESA Funded Activities in Europe 46 Activities to date 16 Countries 18 targeted at TRL = 1-3 24 targeted at TRL = 3-6 Co-funded 4 PhD Studies Total = 25.1 MEuros ESA UNCLASSIFIED - For Official Use Andrew Norman | 18/ 06/ 2019 Ana Brandao | 09/ 05/ 2018 | Slide 13

ESA Funded Activities in Europe  Improved understanding of the End-to-End manufacturing process  Experience in a wide range of techniques and materials  Manufacture and test a number of demonstrator parts  Developing a property database (static and dynamic)  Developing a company database (Europe wide)  Developing a defect catalogue  Create appropriate standards (qualification) ESA UNCLASSIFIED - For Official Use Andrew Norman | 18/ 06/ 2019 Ana Brandao | 09/ 05/ 2018 | Slide 14

Examples of Manufactured Parts I njectors Mirrors Bolts Brackets Nozzles Bellow s Mirrors W ave Guides Optical Bench Cham bers Flex-Pivots Tank Hem ispheres Coils Brackets Brackets Thrusters Brackets ESA UNCLASSIFIED - For Official Use Andrew Norman | 18/ 06/ 2019 Ana Brandao | 09/ 05/ 2018 | Slide 15

Mirror for the Tropomi Instrument (Sentinel 5) Simple reproduction Re-thinking Starting to Design Designing for AM Designing for AM Materials Selection (topology / properties) of existing parts for AM (Alloy design)  Pair of aluminium mirrors set up to form an optical cavity.  Printed in Ti6Al4V using SLM  Requirement of same final coating and optical performance) Original design New design Material: AA6061 Material: Ti-6Al-4V Mass = 284.6g Mass = 127.7g NiP coating NiP coating 56% Mass Saving ESA UNCLASSIFIED - For Official Use Andrew Norman | 18/ 06/ 2019 Ana Brandao | 09/ 05/ 2018 | Slide 16

Single Part Wave Guides Simple reproduction Re-thinking Starting to Design Designing for AM Designing for AM Materials Selection (topology / properties) of existing parts for AM (Alloy design)  Radio Frequency  3D print it in a single piece  Reduce misalignments and errors are removed ESA UNCLASSIFIED - For Official Use Andrew Norman | 18/ 06/ 2019 Ana Brandao | 09/ 05/ 2018 | Slide 17

ISCAR Secondary Bracket for Ariane 5 ECA Simple reproduction Re-thinking Starting to Design Designing for AM Designing for AM Materials Selection (topology / properties) of existing parts for AM (Alloy design)  Part of the Future Launchers Preparatory Programme (FLPP)  Critical secondary structure on the Ariane 5 ECA  Preparation of Bracket qualification for serial production  In flight demonstration on A5 (Pilot) Maturation for A6 ESA UNCLASSIFIED - For Official Use Andrew Norman | 18/ 06/ 2019 Ana Brandao | 09/ 05/ 2018 | Slide 18

Reaction Wheel Bracket for Exomars TGO Simple reproduction Re-thinking Starting to Design Designing for AM Designing for AM Materials Selection (topology / properties) of existing parts for AM (Alloy design) Trace Gas Orbiter ESA UNCLASSIFIED - For Official Use Andrew Norman | 18/ 06/ 2019 Ana Brandao | 09/ 05/ 2018 | Slide 19

Reaction Wheel Bracket for Exomars TGO Simple reproduction Re-thinking Starting to Design Designing for AM Designing for AM Materials Selection (topology / properties) of existing parts for AM (Alloy design) Conventional AM Saving Weight 1114g 456g 60% Buy-to-Fly Ratio 56kg 0.84kg 97% Costs €8000 €3800 53% Lead Time Weeks Days ESA UNCLASSIFIED - For Official Use Andrew Norman | 18/ 06/ 2019 Ana Brandao | 09/ 05/ 2018 | Slide 20

Bellows (Going Small) Simple reproduction Re-thinking Starting to Design Designing for AM Designing for AM Materials Selection (topology / properties) of existing parts for AM (Alloy design)  Failures occurred on welded Ti64 bellows  Artes 5.1 activity to investigate a potentially m ore reliable and cost effective manufacturing process = > AM  Characterizing the performance and the reliability of the bellows ESA UNCLASSIFIED - For Official Use Andrew Norman | 18/ 06/ 2019 Ana Brandao | 09/ 05/ 2018 | Slide 21