Regulatory Perspective on the Use of Metal Additive Manufacturing for Aerospace

Transcription

1 Regulatory Perspective on the Use of Metal Additive Manufacturing for Aerospace Presented at: SME Smart Manufacturing Series: Quality Processes & Regulatory Considerations for Metal AM October 23, 2018 Philadelphia, PA Presented by: Dr. Michael Gorelik FAA Chief Scientist and Technical Advisor for Fatigue and Damage Tolerance

2 Disclaimer The views presented in this talk are those of the author and should not be construed as representing official position, rules interpretation or policy 2

3 Outline Regulatory Considerations Industry Trends Risk Factors and Lessons Learned Role of Public Standards FAA Developments Summary 3

4 AM is Not a Single Process a partial list of metal AM technologies Powder Bed Fusion (PBF) Direct Metal Laser Sintering (DMLS) Laser Freeform Manufacturing Technology (LFMT) Wire + Arc AM (WAAM) 3-D Printing Electron Beam Melting (EBM) Selective Laser Melting (SLM) Additive Layer Manufacturing (ALM) Rapid Plasma Deposition (RPD) Laser Cladding Technology (LCT) Ultrasonic Additive Manufacturing (UAM) Directed Energy Deposition (DED) Laser Engineered Net Shaping (LENS) Laser Deposition Technology (LDT) Different physics different Q&C considerations Lack of common terminology (e.g. L-PBF / SLM / DMLM / DMLS) 4

5 Diversity of AM Processes and Certification Domains By Source of Material: Powder vs. Wire By Source of Energy: Laser vs. e-beam vs. Plasma Arc New Type and Production Certificates Repair and Overhaul (MROs) Aftermarket Parts (PMAs) 5

6 AM - Barrier to Entry Optimistic ~ $1M Equipment acquisition Realistic ~ $10 s of M Process development Process qualification Process controls Material characterization Design data QA / NDI etc. 6

7 Examples of FAA-approved Metal AM Parts Galley Floor Bracket (B-787) 14 CFR Part 25 T-25 Sensor Housing (GE-90) 14 CFR Part 33 Fuel Nozzle (LEAP Engine) 14 CFR Part 33 7

8 State of Industry today + 3 yrs today One Company s Perspective, but Representative of Industry Trends 8

9 Example: Parts Consolidation GE Advanced Turboprop is the first Aviation product to fully utilize additive tools It has 30% fewer parts (from 800+ to 12 parts), and will be completed with a 50% reduction in cycle time From GE 2016 Annual Report 9

10 Example: Moving Towards Full-Scale Production GE Aviation Selects Auburn, AL for High Volume Additive Manufacturing Facility Annual Production Rate of GE LEAP Fuel Nozzle Production will ramp up quickly over the next five years, going from 1,000 fuel nozzles manufactured annually to more than 40,000 by Reference: 10

11 Example: Moving Towards Part Family Qualification Presented by J. van Doeselaar (Airbus) at the 2017 Joint FAA AFRL AM Qual & Cert Workshop, Dayton, OH. 11

12 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 12

13 Regulatory Considerations for AM New Material and Process Space Common consideration for new material or manufacturing technology introduction New Design Space Unique to Additive Manufacturing..? AM can remove many conventional manufacturability constraints ability to produce complex shapes Need to understand impact on parts durability, inspectability etc. 13

14 Evolution of Criticality of AM Parts Criticality Level critical Critical Parts (e.g. CFR Part 25 PSEs, CFR Part 33 LLPs) major effect minor effect * * * * * * * * * * * * * * * * * * * * * * * * * * * * * High Value Parts? Business Value Time Transition to safety-critical applications in aviation will occur sooner than initially expected 14

15 Examples of Risk Factors for AM Surface Quality over 100 process parameters identified Process Controls Microstructure Variability Powder Control Many More Identified by Experts HIP Effectiveness 15

16 Reference: A. Rollett, DOT/FAA/TC-16/15, Summary Report: Joint FAA Air Force Workshop on Qualification/Certification of AM Parts. 16

17 Reference: S. Daniewicz, DOT/FAA/TC-16/15, Summary Report: Joint FAA Air Force Workshop on Qualification/Certification of AM Parts. 17

18 (location-specific microstructure / properties) Reference: A. Rollett, DOT/FAA/TC-16/15, Summary Report: Joint FAA Air Force Workshop on Qualification/Certification of AM Parts. 18

19 Residual Stresses in AM Parts location-specific Crack Initiation (LCF) Crack Propagation (DT) 19

20 Lessons Learned - Examples Structural Castings Effect of material anomalies not well quantified Empirical life management system - design knock-downs (a.k.a. casting factors), classes / grades of castings, etc. Powder Metallurgy (PM) Gave rise to PM-specific fatigue and DT methodologies, explicitly accounting for material anomalies Composites Location-specific and anisotropic properties unique process control and regulatory considerations Defects detectability challenges 20

21 Engagement with SDOs and Consortia A partial list AIA America Makes AMSC AMC SAE FAA KART MMPDS ASTM AWS Next Manufacturing SDOs Consortia, Associations 21

22 Example: Cross-SDO Collaboration AMSC AM Standards Collaborative Can be downloaded at: 22

23 Example: Cross-Committee Collaboration (SDO-level) Multi-Disciplinary Interfaces Are Essential 23

24 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: 24

25 Examples of External Benchmarking 25

26 AM Certification Main Strategic Focus Areas Engineering Certification Production / QA Maintenance / MROs Continued Operational Safety Enablers: Workforce Education (FAA + Designees + Industry) R&D 26

27 Initial AM Documents Are Available at: Policy Search Keyword: Additive 27

28 AM Technology Trends to Watch Transition to full-scale production Use of less expensive raw materials (e.g. lower-grade powders) More aggressive machine settings (speed, layer thickness, ) Use of multi-laser systems Larger build envelopes Introduction of safety-critical parts Topological optimization Longer-Term Tailored location-specific microstructure / properties Replacement of conventional QA / NDI with in-situ process monitoring and adaptive controls Increased use of modeling and simulation in Q&C 28

29 Summary Expect rapid expansion of AM in Aviation and increase in the levels of AM parts criticality Appropriate regulatory framework is a key enabler FAA AIR Transformation new P&I Division Big focus on developing certification approaches for new technologies (Innovation) and collaboration with industry FAA is working on developing a sequence of regulatory documents for AM parts Increased focus on the use of public specifications and standards for Q&C process Industry, agencies and societies collaboration is needed to ensure safe introduction of AM in the National Airspace 29

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

31 APPENDIX AM Q&C References 31

32 2018 FAA EASA AM Q&C Workshop Focus on Q&C of metal AM parts First joint FAA - EASA AM workshop 130+ attendees from industry, government, academia and SDOs representing 9 countries Keynotes: Director of Advance Repairs (Delta TechOps) VP of Product and Process Technology (Arconic) 3 breakout working sessions: o Design Data for Q&C o Fatigue and Fracture Considerations o NDI Inspections and In-situ Process Monitoring Report and full proceedings will be made available to the public 32

33 Legacy Proceedings of FAA AM Workshops ( ) 2017 AM Workshop o External report: AM Workshop o External report: AM Workshop o External report: 33

34 Other AM Q&C References