Ceramics session - Processes for additive manufacturing of large parts, State of the art, locks and design constraints. OLIVIER LARRE, ESTIA Thursday, June 4, 2020
The issue of the keynote Keywords • the different additive manufacturing technologies for large metal parts and mainly the deposition of molten wire and the different suppliers (Sciaky, Gefertec, Prodways, Addilan...), • stresses related to the process material couple • and consequently the parts in question • as well as the target markets , • product design constraints related to the process, • material and use and the expected mechanical properties. • The economic impact of these processes. • Coldspray, FSW for additive manufacturing. Ceramics session RESIM 2020- 4th and 5th of june 2020 2
The Context Metal additive manufacturing "Powder bed" manufacture large metal parts direct energy/material deposition technologies: DED (Direct Energy Deposition) or HDR (High Deposition Rate). processes for depositing material in the form of powder or wire on a substrate Ceramics session RESIM 2020- 4th and 5th of june 2020 3
The Context Processes arising from welding : • Processes based on powder deposition PLAM process gives about 0.25 to 0.6 kg/h maximum Ceramics session RESIM 2020- 4th and 5th of june 2020 4
The Context powder deposition Ceramics session RESIM 2020- 4th and 5th of june 2020 5
The Context Hybrid = powder deposition + machining Ceramics session RESIM 2020- 4th and 5th of june 2020 6
The Context - Processes based on wire deposition : - Here is an explanation of the process (courtesy of Mazak) : Ceramics session RESIM 2020- 4th and 5th of june 2020 7
The Context WAAM process (1.2 mm wire) gives approx. 8 to 10 kg/h maximum Ceramics session RESIM 2020- 4th and 5th of june 2020 8
The Context Ceramics session RESIM 2020- 4th and 5th of june 2020 9
The Context WLAM process (1.2 mm wire) gives about 2 to 3 kg/h maximum Ceramics session RESIM 2020- 4th and 5th of june 2020 10
The Context And finally, weldingless processes have the particular advantage of making it possible to manufacture parts of good metallurgical quality with low porosity without welding and therefore without excessive residual stresses: • Processes similar to Cold Spray: • Speed3D Ceramics session RESIM 2020- 4th and 5th of june 2020 11
The Context - Processes close to FSW : - MELD https://www.youtube.com/watch?v=a mRccXbJFEs Ceramics session RESIM 2020- 4th and 5th of june 2020 12
The Context A very strong trend at the moment is therefore to use 6-axis robots. Many research centers in France and around the world are working on this. Among the most dynamic are Cranfield University on the large WAAM and, in France, entities such as the Welding Institute on the CMT, the LIRM, the Maupertuis Institute, Centrale Nantes... or Estia and its Addimadour platform. For this purpose, many suppliers offer heads / effectors. Ceramics session RESIM 2020- 4th and 5th of june 2020 13
The Context As seen previously, multi-axis direct deposit techniques are currently undergoing strong development because they offer : • larger working dimensions, • Possibility of rework on parts ( repair, addition of functions.. .) • Process Hybridization • and can be combined with machining processes. The multi-material approach is also easily possible with these processes. Ceramics session RESIM 2020- 4th and 5th of june 2020 14
The Stakes • Design – CAD Re-designing parts and designing for AM (Design for AM) is a key factor i n making the process interesting. Limitations of existing software: how to design a part for the DED process, how to take into account aspects such as multi-materials Autodesk • CAM The generation of trajectories is an issue common to all direct deposit processes. Taking into account thermal issues when generating trajectories is also an area of research. The influence of the overall trajectory , the filling strategy, the manufacturing strategy in the broadest sense is enormous on the metallurgical quality of the part as well as in terms of residual stresses. Ceramics session RESIM 2020- 4th and 5th of june 2020 15
The Stakes • Simulation Process simulation, especially for wire deposition and the manufacture of very large parts, becomes essential to predict and counteract deformations due to residual stresses and to manufacture a good part the first time. ESI, Virfac • Digital continuity of software The preceding points show the need for a strong numerical integration from CAD to CAD/CAM through simulation, some software publishers are beginning to offer complete suites: Siemens with Siemens NX, Dassault Systèmes with 3DExperience. Ceramics session RESIM 2020- 4th and 5th of june 2020 16
The Stakes • Manufacturing The manufacturing process must take into account not only the additive manufacturing part itself but also the post-processes necessary or not ( thermal treatment , HIP, dimensional control, material health (which methods?...)). The material flows and the industrial and logistic organization must be rethought with the arrival of this new means of production in the workshop. • Industrialization and Make or Buy DED processes are still generally in the laboratory domain (except for a few concrete cases), so it will be necessary to go through an industrialization phase (industrialists and not labs taking over the means) and therefore decide for the principals whether to do in-house or to subcontract (depending on the need to integrate the skills to evaluate the techno, the strategic importance of certain parts, etc.). Ceramics session RESIM 2020- 4th and 5th of june 2020 17
The Stakes • Costs, Deadlines, Quality Additive manufacturing by metal wire deposition is a process that many manufacturers are banking on to reduce the cost of manufacturing parts in the future. Indeed, this very flexible technology has many advantages over other additive manufacturing processes: - low investment (of the order of 100 to 500 k€, compared to 600 k€ to 1.5 M€ for powder bed processes and 800 k€ to 2 M€ for powder spraying), - large working space (several meters), of course subjects such as inerting for materials like Titanium still remain partly to be solved (local inerting, overflow tank, inerting of the whole manufacturing space ...) Ceramics session RESIM 2020- 4th and 5th of june 2020 18
The Stakes - “high productivity" (several kg/h as opposed to a few g/h), this should make the process economically viable, even if it remains slow . The advantage of being able to do without long lead times compared to forged or castings is important. - good metallurgical quality (defects similar to welding, no porosities...), - little downtime and material loss, - low cost and quick material changeover, Ceramics session RESIM 2020- 4th and 5th of june 2020 19
The Stakes - the materials currently addressed are the weldable materials but the emergence for the additive manufacture of old techno like ColdSpray or FSW (Friction Stir Welding) makes it possible to address the manufacture of certain aero-non-weldable materials for example, but also to free oneself from certain constraints due to the process, ( residual thermal constraints in particular). Ceramics session RESIM 2020- 4th and 5th of june 2020 20
The Stakes • Health, Safety and Environment (HSE) The HSE constraints linked to powder additive manufacturing are heavy, even if for LMD processes, they are a little less so given the size of the powders (45-75 μm, variable according to material). We can mention the need to have an isolated room managed in hygrometry and temperature, preferably with a vacuum. The intervention of the operators is preferably done in combination and with a recirculating air mask. On the other hand, there is a reduction in HSE risks for wire technologies compared to metal powders. Ceramics session RESIM 2020- 4th and 5th of june 2020 21
The Stakes • Certification New processes require new modes of certification. In the aeronautical sector in particular, few parts are currently flying in relation to the overall volume of parts. • Training Specific training courses are beginning to be developed in engineering schools in the form of modules or complete training courses for initial training. Training modules are also available for industrialists in post (particularly in engineering and design). Ceramics session RESIM 2020- 4th and 5th of june 2020 22
Conclusion There are many processes (from welding and research centres) and suppliers on the market, however TRL levels are often intermediate (3-5). The target markets are the manufacture of large parts (stiffeners...) in the form of parts close to the final shape or blanks which in all cases will require post-treatment by machining, or even thermal treatment. These technologies make it possible to address the addition of function, repair, multi-material manufacturing, and the production of blanks by an alternative process to casting or forging. The most dynamic sectors are aeronautics and space, even if markets such as energy, oil & gas and naval are investigating the use of these technologies. Ceramics session RESIM 2020- 4th and 5th of june 2020 23
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