Progress Update On Manufacturing Process Enhancement Through Additive At Large Scale With Metals

Transcription

1 Progress Update On Manufacturing Process Enhancement Through Additive At Large Scale With Metals Andrzej Nycz Mark Noakes ORNL is managed by UT-Battelle, LLC for the US Department of Energy

2 Outline MBAAM program MBAAM Excavator case Tooling Capabilities now and Tomorrow Results Conclusions 2

3 Results Conexpo d printed excavator live demo for 130k people IMTS 2018 Die in a day Stamping dies Multi axis prints Multi material 3

4 Metal Big Area AM Goals (MBAAM) Create large parts with suitable mechanical properties Feasibility Productivity Quality Economy Scalability Disrupt the status quo? 4

5 What is considered large? Starts at 3-6ft (1-2m in the longest axis) Applications Tooling!!! Aviation, construction, mining, shipyard, large machinery,? 5

6 MBAAM Definitions, AM and welding 3D printing, also known as additive manufacturing (AM), refers to processes used to create a three-dimensional object in which layers of material are formed under computer control to create an object. Object creation 3 dimensional Layered (not a requirement) Computer controlled and generated (digital) Arc welding is a process that is used to join metal to metal by using electricity to create enough heat to melt metal, and the melted metals when cool result in a binding of the metals. Wikipedia Arc-wire AM not welding???? 6

7 MBAAM - AME Case Study AME- Additively Manufactured Excavator Demonstration of large scale metal printing complex metal objects with medium near net shape accuracy (excavator arm with embedded hydraulics). For large, complex metal objects with medium near net shape accuracy. Up to 8ft tall.` Low cost, large build envelope, higher production rate, and wellestablished supply chains. 7

8 AME Challenges Deposition process development Geometric feature characterization Robotic path and integration Heat management Slicing Material properties Mechanical design Machining September 2016 Hardware delivery, Jan ft arm printing, March 7th 2017 Conexpo in Las Vegas. 8

9 AME Challenges - Deposition Process Development Vertically or horizontally? Print table (not trivial), plates clamps etc. 1 thick plates, clamps MIG STT welding process with bead tracking, Argon/CO2 mix Wire type ER70S , Closed loop control in contrast to usual open loop Bead overlap Lincoln Powerwave S500 with Autodrive SA wire feeder 9

10 AME Challenges- Geometric Features Characterization Layers, beads, overlap, infill, Insets How wide, how high, how to deposit? When to use infill when to use insets/perimeters Engine block example -> 10

11 AME Challenges - Slicing ORNL Slicer - new Wolf branch G-Code only for geometry expression Scale, features complexity, bead definition, start and stop choice, tip wipes, skeletons, order of beads, heating and cooling, curve smoothing tolerance, first layer settings, direction of printing 11

12 Results Conexpo 2017 Live demo for 130k people 927 layer, 5days and 90 min print close to 400lb, 14 miles of wire, 7ft tall 1mm height error! 12

13 Excavator Arm Simulation and Modelling Temperature Deformation Residual stress Properties 13

14 MBAAM tooling- why and what? Production automotive tooling. Same message from all automotive companies: Tooling costs >$200M/model/yr Stamping dies generally exceed $500K Lead time is 2 to 3 years In 2009, there were 230 new and existing car models offered in the US. $1.3T in sales Approximately 17.5 million vehicles sold in 2017 U.S. tooling is expected to be $15.2B in Each tool in unique (one of a kind) and complex. Additive s strength! AM can transform the automotive production tooling industry. Total import of tools in billions $$ (Japan, Canada, Korea)

15 Tolling and AM Feature removal Small features, threads, holes Features not taking advantage of AM Augment, not compete with conventional ways Machining almost always required 15

16 Tolling and AM Identification of important features Role of the tool? Surfaces have to be machined Loading conditions? Mech properties- hardness material choice 16

17 Tolling and AM Divide and conquer Zone and strategies Quality vs productivity when and how The best quality when it matters The highest speed elsewhere Machining and extra material Process surface roughness? Pattern strategy artefacts Acceptable imperfections 17

18 Tolling and AM Hot stamping Cooling/heating channels Challenge for conventional manufacturing AM free Shape freedom Flow 18

19 Capabilities - System Hardware 6 DOF IRB 2600 ABB arm + 2 DOF Positioner GMAW (MIG) PowerWave S500 Welder Commercial off the shelf and low cost Build workspace Build table (4x3 x 8 ) stationary, Positioner (3x3x5 ) Limit - arm size (upgradable), table(upgradable) Multi-material Near net shape Low cost feedstock 19

20 Capabilities - System Closed Loop control x3 Part sensing Surface following Height control Sensing Temperature (IR, thermocouples) Welding conditions System variables system status logging 20

21 Capabilities Mech properties so far Isotropic properties No porosity or systematic voids Pressure tested up to 5kpsi, vacuum 10-9 Torr Mild steel YS 94-96%, UTS and elongation equals or better than welding standards (AWS) Materials tested or in the works: ER70S6, ERS100, ER410 (SS), maraging steel, Invar Materials tested on dozens of parts, not a single sample 21

22 Capabilities Deposition rates and path generation True 3D printing computer generated path Custom ORNL slicer and partner s slicer Flat slicing OR 8+ axes coordinated motion (real 3D) 5-15lb/h Multi-material deposition - computer generated, within the same part! 22

23 What can and makes sense today Augment instead of replacing CNC workshops Learn and take advantage do not print blocks of metal! Apply when makes sense and mix and match with conventional Design/modify for AM instead of print me this part Tools, tools and tools Construction, mining, shipyard, large machinery 23

24 24 Tomorrow Deposition rates 100lb/h+ Increased single head depositions 40lb/h in testing Multi robot depositions (3 robot station at ORNL) MedUSA Multi robot farms 10 + robots deposition Volumes 10x10x10m + Print by Wire Sense Path regeneration Correct Realtime Print prediction simulation Hybrid AM, Laser, Arc, Powder, Wire, CNC

25 Scaling up Main constraints Feedstock wire vs powder Safety storage and delivery Shielding and print chamber Local shielding (torch) (MIG) Inert chamber (Argon) Vacuum chamber Workspace All the above Gantry vs Robot Both 25

26 Results: stamping/forming Stamping die Material: Mild steel Printing and machining in 24h 12x6x6 Worth about 3k$ 26

27 Results IMTS forming and compression molding IMTS Chicago show 5 sets of dies Printing and production live 27

28 Results Hot stamping die Internal cooling channels and manifolds Progressive die 80k cycles test Material: stainless steel 38 Multilateral die Stainless skin Mild core 28

29 29 Results - Recent Propeller (Propulsor)

30 Conclusions Tooling attractive for large scale metal Augment rather than replace High accuracy - smart strategy for path control Near net shape Low cost feedstock Ready for testing today 30

31 Acknowledgments The Team Lonnie Love, Suresh Babu, Chris Masuo, Derek Vaughan Alex Arbogast, Jacob Fowlers, Steven Patrick, Rachel Harris, Mark Noakes, Andrzej Nycz Wolf Robotics: Mark Shaub Johnathan Paul (JP), Jason Flamm Lincoln Electric Tom Mathews, Andrew Peters, Badri Narayanan This material is based upon work supported by the U.S. Department of Energy, Office of Science, Office of Energy Efficiency & Renewable Energy, Advanced Manufacturing 31

32 Questions? Contact: Andrzej Nycz Manufacturing Systems Researcher Oak Ridge National Laboratory Visitors welcome Industrial partners Students, interns, co-ops, Post BS, MS, PostDocs 32