European Raw Additive Manufacturing Material Procurement For Space Applications

Transcription

1 European Raw Additive Manufacturing Material Procurement For Space Applications Dr Laurent Pambaguian Materials Technology Section 13/10/2016 Issue/Revision: 0.0 Reference: ESA UNCLASSIFIED Status: - For Official Use ESA UNCLASSIFIED - For Official Use

2 Gastronomy Vs Space Innovate and create new flavours and textures Manufacture in small series or even have unique creations Keep up with stock and storage requirements Deal with limited shelf-life materials Cope with tight schedule and parallel processes Run the show flawlessly errors are not permitted. Mix state-of-the-art and advanced technologies with highly skilled operators Exchange and ensure satisfaction of customers ESA UNCLASSIFIED - For Official Use Dr Laurent Pambaguian - Materials Technology Section ESTEC 13/10/2016 Slide 2

3 Gastronomy Vs Space Materials Processing include precisely mastered: Dilution of liquids and powders Controlled crystallisation Incursion at temperature from cryogenic to several hundred Celsius Extrusion, lamination, granulation Hardening and softening of bulk and coatings Multi-layering, assembling, bonding Mixing, foaming, thickening All chefs say that they rely on top quality ingredients They all have well established ingredient providers ESA UNCLASSIFIED - For Official Use Dr Laurent Pambaguian - Materials Technology Section ESTEC 13/10/2016 Slide 3

4 Space business applications Earth observation, science, manned: 1 to 5 Launchers: 5/year NEW! Constellations: ESA UNCLASSIFIED - For Official Use Dr Laurent Pambaguian - Materials Technology Section ESTEC 13/10/2016 Slide 4

5 Space segment environmental requirements Ground Launch Service temperature, contamination, humidity, corrosion, transport loads, tests, ageing, storage vibrations, shocks, accelerations, birds, thermal fluxes, venting temperature, thermal cycling, vacuum (outgassing), radiation & particles, electrical charging, fluid compatibility, ATOX, micrometeorite, ageing ESA UNCLASSIFIED - For Official Use Dr Laurent Pambaguian - Materials Technology Section ESTEC 13/10/2016 Slide 5

6 Why additive manufacturing for Space? Space M&P challenges Small material quantities difficult material procurement Small number of identical parts affordable processes limited Initial benefits for space industry Means of alleviating material procurement issues - feed stock is re-useable. Means of replacing unaffordable processes. Other benefits for space industry Design for performance low mass Reduce lead-time Suppress interfaces controls Conceive new missions ESA UNCLASSIFIED - For Official Use Dr Laurent Pambaguian - Materials Technology Section ESTEC 13/10/2016 Slide 6

7 Additive manufacturing from ESA perspective ESA UNCLASSIFIED - For Official Use Dr Laurent Pambaguian - Materials Technology Section ESTEC 13/10/2016 Slide 7

8 Manufacturing of band-pass filter ESA UNCLASSIFIED - For Official Use Dr Laurent Pambaguian - Materials Technology Section ESTEC 13/10/2016 Slide 8

9 Change in design approach Designed for manufacturability Designed for performances ESA UNCLASSIFIED - For Official Use Dr Laurent Pambaguian - Materials Technology Section ESTEC 13/10/2016 Slide 9

10 Change in Material Selection Main requirements: Specific stiffness Thermal conductivity Coefficient of Thermal expansion Electrical conductivity Corrosion and stress corrosion cracking resistance (SCC no go for structures) Molecular & Particle Cleanliness and cleanability Radiation resistance ATOX resistance (low Earth orbit only) Coating / surface treatment compatibility Less important Specific strength Fatigue resistance Optical mirror Redesign while changing material (from Al r=2.7 to Ti r=4.5): lighten the part by 50% keeping decoupling between optical surface and attachment ESA UNCLASSIFIED - For Official Use Dr Laurent Pambaguian - Materials Technology Section ESTEC 13/10/2016 Slide 10

11 ESA harmonisation on ALM Harmonisation dossier on Additive manufacturing Nov introduction of AM o ESA national Delegates Feb Mapping meeting Oct 2014 AM workshop at ESTEC -350 delegates May 2015, endorsement by ESA national Delegates of the Harmonisation Dossier Aim B: Design for AM Aim C: Consistent European raw material supply chain. Aim D: AM processing Aim E: Post-AM processing (e.g. surface finish) Aim F: Qualification, acceptability criteria for parts Aim G: Normative framework for the above aims ESA UNCLASSIFIED - For Official Use Dr Laurent Pambaguian - Materials Technology Section ESTEC 13/10/2016 Slide 11

12 Raw material for 3D printing housing on the moon Background and issue: ESA founded a GSP study (low TRL) to assess possibility of using lunar regolith as raw material for 3D printing. Selected consortium designed a building concept of a lunar base. To demonstrate feasibility, it required 3 tons lunar regolith simulant. No European sources existed Cost to purchasing regolith simulant from existing sources was higher than study budget Way forward A member of the consortium travelled in Italy and analysed quarries from volcanos Using analysis, mixed volcanic hashes to get chemistry very close to lunar soil analysis Today, DNA-1 can be purchased from European source at competitive price. ESA UNCLASSIFIED - For Official Use Dr Laurent Pambaguian - Materials Technology Section ESTEC 13/10/2016 Slide 12

13 Change in mission scenario ESA UNCLASSIFIED - For Official Use Dr Laurent Pambaguian - Materials Technology Section ESTEC 13/10/2016 Slide 13

14 Raw material for 3D printing 10 N thrusters Background and issue: ESA founded an ARTES study (telecommunication satellite) to assess possibility of using ALM for chemical propulsion with C wall temperature. Consortium selected LBM of a Platinum alloy as base material. No source existed worldwide Way forward Consortium developed atomisation of Pt alloy of interest. Consortium established process parameters for LBM and mechanically tested material. Thruster has been manufactured and successfully fire tested. This is the 1 st 10N thruster worldwide Change in Industrial set-up? ESA UNCLASSIFIED - For Official Use Dr Laurent Pambaguian - Materials Technology Section ESTEC 13/10/2016 Slide 14

15 Raw material procurement chain General issue: the traceability of raw material is difficult to ensure Some machine manufacturers sell powder and they can have more than 1 source. It is unclear from ESA perspective if documentation allows end customer tracing back powder provider. According to some end users, the characteristics of the powder bought from a machine manufacturer would have changed at a point in time requiring a new tuning of additive manufacturing process parameters. Some powder manufacturers are making made-to-measure powders the origin of the raw material is not necessarily fully clear. Some powder manufacturers can deliver small quantities of special powders. Are those exotic materials made on demand or purchased? For very expensive powder (e.g. Platinum based) close loop cycle would be required for cost issues the AM machine should be at the powder producer premises. Access to information may be tricky. The need to maintain traceability can encompass the multiple use of the same powder in a company (always in the same machine or in different machines) In case the raw material is sent back to raw material producer impact of recycling in the atomisation process has not been looked at (as far as I know). ESA UNCLASSIFIED - For Official Use Dr Laurent Pambaguian - Materials Technology Section ESTEC 13/10/2016 Slide 15

16 Raw material assessment at ECSAT Background and issue: ESA established a laboratory to perform independent material assessment in U.K. Routine evaluation methodology is under development for ALM powder. Powder samples sent by different entities help better understanding powder characterisation techniques / requirements. This has just started few months ago Way forward Learn from the others Understand documentation requirements Characterise powder vs ideal powder Assess impact of environment Assess impact of recycling Establish guidelines for procurement ESA UNCLASSIFIED - For Official Use Dr Laurent Pambaguian - Materials Technology Section ESTEC 13/10/2016 Slide 16

17 Concluding remarks Additive Manufacturing is considered as enabling technology in Space Industry. Need to ensure high reliability while dealing with low volumes implying: Short term: keeping all process characteristics as for the part qualified Longer term: understanding correlation between material and process to qualify at affordable cost Even longer term: develop materials for Additive processes the same way wrought alloys were developed for machining. Tuning materials toward a specific application requirements ESA will hardly lead the way for generic raw materials but will work with all space stakeholders to ensure high reliability procurement of those. Based on the above, ESA will ensure that European Space Industry maintain access to high-end raw materials for AM, preferably sourced in Europe. ESA UNCLASSIFIED - For Official Use Dr Laurent Pambaguian - Materials Technology Section ESTEC 13/10/2016 Slide 17