Summary of the Recent AM Activities at the FAA

Transcription

1 Summary of the Recent AM Activities at the FAA Presented to: AMMO Working Group October 4, 2017 (via telecon) Presented by: Dr. Michael Gorelik FAA Chief Scientist and Technical Advisor for Fatigue and Damage Tolerance

2 Agenda 3 rd Joint FAA AFRL AM Workshop on Qualification & Certification of Metal AM Parts Recent organizational changes at the FAA FAA Strategic AM Roadmap 2

3 3 rd Joint FAA AFRL AM Workshop Agenda at a Glance Keynote VP and GM, GE Additive Over 30 presentations from industry, government and academia Panel on AM Training and Education Professional Networking 3

4 Workshop Evolution ( ) 2015 Workshop First in the series (for FAA) Focus on overview of AM technologies and identification of potential certification concerns and considerations First exposure to AM for many FAA attendees Main focus on getting perspective from the government agencies and major OEMs 2016 Workshop More in-depth discussions on specific qualification approaches reflect industry progress (some presentations are benchmarked by industry working groups) Expanded coverage to include supply chain perspective (Tier 1, raw materials, ) Continued education of FAA workforce Significant coverage of government AM activities 2017 Workshop First global workshop open to foreign participants, including several NAAs Twice bigger than the prior workshops significantly expanded industry demographics Focused Training & Education panel Continued Q&C topics coverage, including process monitoring, part family and feature-based qualification etc. Progress on AM standardization 4

5 2017 Workshop Demographics Major suppliers Machine Makers OEMs MROs / Repairs /Aftermarket Small business FAA US Govt Non-US Govt USAF Societies Institutes Academia Non-aviation cert DER 5

6 Global Participation in

7 US Government Foreign Governments 7

8 Additive Manufacturing New Paradigm: Manufacturing Capabilities Ahead of Design Vision..? Additive manufacturing is the new frontier. It has taken the shackles off the engineering community, and gives them a clean canvas Mr. David Joyce, GE Aviation President and CEO 8

9 Regulatory Considerations for AM New Material and Process Space Common consideration for new material or manufacturing technology New Design Space Unique to Additive Manufacturing..? 9

10 Key Workshop Takeaways High rate production of AM parts is now a reality The GE AM fuel nozzles for the LEAP engine are now in production at a rate of thousands of units per year Many specific applications of AM are now under development, and appear targeted for near-term implementation Extensive efforts to develop AM standards, specifications, and guidelines continue: AMSC developed a Standards Roadmap for AM, including gap identification in AM standards and specifications The following considerations must be addressed for AM Q&C: Machine and supplier qualification Quality control of input metal powder Characterization and control of process-related defects and anomalies NDE requirements and capability Software and hardware version control and protection Post-deposit processing such as HIP, heat treatment and surface finish Frozen processes with feedback and monitoring mechanisms 10

11 Workshop proceedings are being published and will be available In the meantime, here are the proceedings of the 2016 FAA-AFRL AM Workshop: 11

12 FAA Organizational Update Re-alignment of the Aircraft Certification Service (AIR) organization 12

13 Pre-realignment AIR Structure ( AIR = FAA Aircraft Certification Service ) Transport Airplane Directorate (14 CFR Part 25) Small Airplane Directorate (14 CFR Part 23) Engine and Propeller Directorate (14 CFR Parts 33, 35) As of July 23, 2017, the Divisions and Directorates listed below no longer exist as part of AIR's organizational structure; as part of AIR Transformation, the personnel, functions, and responsibilities of these offices have been incorporated into the Functional Divisions (see next slide) - Eng & Mfg Division (HQ) Rotorcraft Directorate (14 CFR Parts 27, 29) - 4 Directorates - Multiple Cert offices 13

14 AIR Transformation (effective ) Aircraft Certification Service (AIR) Policy and Innovation Compliance and Airworthiness System Oversight Organizational Performance Foundational Business The Policy & Innovation Division supports aerospace innovation by creating novel means of compliance, develops and maintains AIR regulations, manages the CSTA program and overall fleet safety, as well as educational outreach. Public-facing AIR Transformation Web Site: 14

15 Concept of Innovation Centers Key element of the new AIR Policy & Innovation function Provides robust mechanism to address new technologies and MOC (means of compliance) Late awareness can result in project delays Be more proactive prior to the initial project application Identify new technology or MOCs beyond the scope of existing regulations and policy Supports FAA efforts to streamline certification process Success is dependent on OEMs buying into the concept Early engagement - Company proprietary / intellectual property concerns Emerging technologies similar to AM will be addressed by Innovation Centers once they are implemented 15

16 FAA AM Strategic Roadmap 16

17 Excerpts from AMNT Charter AIR-100 management requested the development of a roadmap for determining the needs for policy and guidance along with any training for certifying projects utilizing AM parts. The roadmap will be developed and implemented by the Additive Manufacturing National Team (AMNT) which will require resources, input, and support from AIR directorates, Flight Standards and offices. The roadmap will identify FAA concerns and recommendations to insure application of robust and consistent safety standards for design, manufacture and field management of AM products. The development of this roadmap will require coordination with other government agencies, academia and industry organizations. 17

18 Examples of Expanding Use of AM GE Advanced Turboprop is the first Aviation product to fully utilize additive tools It has 30% fewer parts (from 800+ to 15 parts), and will be completed with a 50% reduction in cycle time From GE 2016 Annual Report By 2018 Airbus expects to print about 30 tons of metal AM parts every month, according to a company statement 18

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20 AM Roadmap Main Focus Areas ( swimlanes ) (1) Engineering Certification (2) Production / QA (3) Maintenance / MROs (4) COS Enablers (5) Workforce Education (FAA + Designees + Industry) (6) R&D 20

21 Key Elements of the AM Roadmap Content (4 regulatory swimlanes) Key Risk Factors Regulatory gap analysis Proposed new or revised documents (policies, ACs, ) No rule changes expected Key Tasks and Project Plan (high level) Inter-dependencies between the 4 swimlanes Input into R&D and Training swimlanes 21

22 AM Roadmap Timeline Projected AM Roadmap Span (notional timeline will be populated as feasible) Prioritization of Roadmap tasks FY18-20 tactical project plan 22

23 External Benchmarking 23

24 Strategic AM Roadmap Submitted to Management for Review (end of FY17) D R A F T 24

25 Summary AIR Transformation new P&I Division Big focus on developing certification approaches for new technologies (Innovation) and collaboration with industry First FAA AM Roadmap will be finalized later this year Provides a sequence of regulatory documents (policy, guidance, ) to be developed over the next few years No rule changes are envisioned at this time Roadmap is a living document - will be revisited / updated annually Very large scope - collaboration with other agencies and industry / societies / academia is important: Qual and Cert experience R&D Training and Education 25

26 Questions Dr. Michael Gorelik, PMP Chief Scientist, Fatigue and Damage Tolerance Aviation Safety (480) , x