3D-Drucker/Generative Fertigung Wie sich die Produktion ... · © Fraunhofer ILT Static mechanical...

© Fraunhofer ILT

3D-Drucker/Generative Fertigung – Wie sich die Produktion verändert und die Logistik vor neue Herausforderungen stellt

Adj. Prof. (RMIT) Vis. Prof. (NUAA) Akad. Oberrat Dr.-Ing. Ingomar Kelbassa

Dr.-Ing. Andres Gasser

Dr.-Ing. Dipl.-Phys. Wilhelm Meiners

Dipl.-Phys. Christian Hinke

Dipl.-Ing. Gerhard Backes

Logistiktag 2014, Kassel, Germany, June 25, 2014

© Fraunhofer ILT

Content

Motivation

Process basics

Developments & Applications

Digital Photonic Production

© Fraunhofer ILT

Value Change

„Dynaxity“

New Production

Mobility and Transport

Energy Consumption and Resources

Climate Change

„Fraunhofer Gesellschaft Z punkt.-Lebenswelten 2015 plus“, „Siemens-Horizons 2020“

Health

Globalization

Knowledge Society

Change of Work

Political Conflicts

Demographic Change

Mega Trends

© Fraunhofer ILT

Lot size

Conventional Production

Cost

Direct Photonic Production



Increase in deposition rate = Decrease in cost! „Time is money“

© Fraunhofer ILT

Content

Motivation

Process basics



© Fraunhofer ILT

Laser Material Deposition LMD >> 1 step process <<

© Fraunhofer ILT

Selective Laser Melting SLM >> 2 step process <<

Metal powder Lowering of platform

Selective melting of powder layer

Deposition of powder layer

Metal part made from serial material

3D CAD model, sliced into layers

© Fraunhofer ILT

Selective Laser Melting SLM – Basic Principle

Laserstrahl

umgeschmolzene

Schicht

Schmelzbad

Bewegungsrichtung

des Laserstrahls

Pulverschicht

laser beam

scan direction

powder layer

solidified layer

melt

use of serial material

complete melting of the

powder particles

part density of 100%

preheating device

enables processing of a

wide range of materials:

- Titanium alloys

- Aluminum alloys

- Steel

- CoCr alloys

- Nickel alloys

beam diameter

layer thickness

track distance

© Fraunhofer ILT

SLM LMD characteristics

materials large materials

diversity

• limited and lower experience in comparison to LMD

limited by the handling system

limited by the process chamber

(ø : 250 mm, height : 160 mm)

part dimensions

limited nearly unlimited part complexity

0.1 mm 0.1 mm dimensional accuracy

• 3D-surface • on existing parts

• flat surface • flat preforms

build-up on

3 – 10 mm3/s 1 – 3 mm3/s deposition rate

60 – 100 µm 30 – 50 µm roughness Rz

0.03 - 1 mm 0.03 - 0.1 mm layer thickness

Selective Laser Melting (SLM)

Laser Metal Deposition (LMD)

Comparison of the characteristics SLM / LMD

© Fraunhofer ILT

Content

Motivation

Process basics



© Fraunhofer ILT

Fields of expertise for process development

Systems engineering Process layout Materials

Process monitoring Beam source(s) Process fundamentals

100 µm

© Fraunhofer ILT

BLISK – BLade Integrated DiSK or BLaded DISK

Source: Rolls-Royce Deutschland Ltd & Co KG Compared with conventional parts:

Pro: Lower weight (- 30 %)

Pro: Higher pressure ratio / stage

Pro: Smaller moment of inertia

Higher specific efficiency

Saving of resources

Con: High manufacture / repair costs

© Fraunhofer ILT

BLISK manufacture today and tomorrow

From material removal (Stone Age thrugh today)…

…to additive manufacture (tomorrow)

+ =

© Fraunhofer ILT

Static mechanical properties I

UTS0.2%-YS

1088

962

1100

900

1332

1155

924

594

965

575

1240

1030

1340

1100

0

200

400

600

800

1000

1200

1400 N/mm2

End user specs.

Heat treted raw material, literature

Annealed hot-rolled raw material

LMD without heat treatment

LMD with heat treatment

End user specs.


20 °C

650 °C

Confirmed

© Fraunhofer ILT

Static mechanical properties II

Elongation

1110

15

35

45

1210

0

5

10

15

20

25

30

35

40

45

%

End user specs.

Heat treated raw material, literature

Annealed hot-rolled raw material

LMD without heat treatment


End user specs.


20 °C

650 °C

Confirmed

© Fraunhofer ILT

Dynamic mechanical properties (HCF, 1C mode)

2,27 2,212,28

0,00

0,20

0,40

0,60

0,80

1,00

1,20

1,40

1,60

1,80

2,00

2,20

2,40

2,60

2,80

3,00

Failu

re lim

it [

mH

z]

LMD with heat treatment Raw material Theoretically predicted by Holographic Mode Shape Analysis

Max. movement (leading and trailing edge)Max. stress (tip middle)

Riss

20 mm

Riss

20 mm

Confirmed

Crack Crack

© Fraunhofer ILT

LMD diagram

Scanning speed La

ser

po

wer

Po

wd

er

mass

flo

w

2

[Powder efficiency, deposition rate]

[Porosity]

PL2

mP1,2

vV1,2

1

PL1

Available laser power max. (10 kW)

Ava

ilab

le s

can

nin

g s

peed

max.

Available powder mass flow max.

Depiction of appropriate process windows for a constant track width

Information regarding porosity

Information regarding powder efficiency

Track width

© Fraunhofer ILT

LMD of cuboids

η > 60 %

η > 60 % η > 70%

η > 80 %

η = powder efficiency

1

2

1

2

2

1

© Fraunhofer ILT

Collimation

Optics

Coaxial, continuous

ILT powder nozzle D40

manual

version

automatic

version

20 cm

Adjustment

motor

Zoom optics for on-line variation of laser beam diameter

© Fraunhofer ILT

HPC FRONT DRUM HCF TEST SPECIMEN

(Source: Rolls-Royce Deutschland Ltd & Co KG)

Process strategy for blade build-up

Layer n

Layer n+1

Near-net-shape build-up of BLISK blade mock-ups

Points of support Start Finish

© Fraunhofer ILT

Additive manufacture of one BLISK blade in t < 2 min. (near-net-shape)

Near-net-shape build-up of BLISK blade mock-ups

© Fraunhofer ILT

Laser Metal Deposition LMD

Process

BLISK Blade additively manufactured by LMD

© Fraunhofer ILT

Ferchau Innovation Award 2011 Additive BLISK Manufacture by Laser Material Deposition LMD

Hannover Trade Fair April 04, 2011

© Fraunhofer ILT

Innovation Challenge Award (Aviation Week) in the Category “Power and Propulsion” Additive BLISK Manufacture by Laser Material Deposition LMD

Washington, D.C. March 07, 2012

© Fraunhofer ILT

Ultra high-speed LMD

Classification of LMD processes by process velocity/ feed rate: Pulsed LMD vv = 0 mm/min

Low-speed LMD vv = > 0 – 200 mm/min

Standard LMD vv = 200 – 2,000 mm/min

High-speed LMD vv = 2,000 – 20,000 mm/min

Ultra high-speed LMD vv = 20,000 – > 100,000 mm/min

© Fraunhofer ILT


http://www.hazmat-alternatives.com/Alt_tech-Chrome.php

Replacement of Thermal spraying (APS, VPS, HVOF etc.)

Chromium plating

by LMD (thin layers between 25 and 200 µm) due to process specific advantages such as Metallurgical bond

Factor of min. 10 higher process speed

compared to conventional LMD

Smoother surface finish

http://www.advanced-coating.com/english/spraying.htm











© Fraunhofer ILT


Principle

Laser radiation

Powder gas jet

HAZ HAZ

Conventional LMD Ultra high-speed LMD

Ap = 20 – 30 % vv = 1,000 – 2,000 mm/min

Ap = 80 – 90 % vv = 100,000 – 500,000 mm/min

Tp ≈ Tm

© Fraunhofer ILT


Process velocity vv = 200,000 mm/min

© Fraunhofer ILT

100

150

200

250

300

350

400

0,00 0,05 0,10 0,15 0,20 0,25 0,30 0,35 0,40 0,45

Har

dn

ess

[HV

]

Distance [mm]

Coating HAZ Substrate

Inconel 625


© Fraunhofer ILT

LMD of a shaft used in off-shore apps. Weight of shaft: 1000 kg Process velocity vv

up to 50,000 mm/min Laser power 4000 W


© Fraunhofer ILT

Laser Additive Manufacturing – Automotive Applications

Blankholder side panel

Pulley

Chassis component

Kinematics component

Blankholder

Blankholder

Holder gas-filled absorber

Closure clamp

Chassis component Damper intake

Luggage rack holder

Kinematics component seat adjustment

HKL hinge

Brake line holder

Hose holder

Heat protection blank steering gear

Source: N. Skrynecki, Kundenorientierte Optimierung des generativen Strahlschmelzprozesses, 2010

© Fraunhofer ILT

First SLM Hip Cup

Bone substitute implants with mesh structure made from TiAl6V4

Conventional manufacturing not possible

Improvement of bone-implant interaction

Hip cup manufactured at ILT implanted in January 2008

© Fraunhofer ILT

Actual Reseach Topics/ Precision: Dimensional Accuracy

Target: 64,00 mm Actual: 63,98 mm

Target: 64,40 mm Actual: 63,36 mm

© Fraunhofer ILT

High power SLM for Aluminum

Material: AlSi10Mg PL: 200 W Beam diameter: 200 µm Scan speed: 800 mm/s

Material: AlSi10Mg PL: 1000 W Beam diameter: 200 µm Scan speed: 2000 mm/s

© Fraunhofer ILT

skin layer (50

µm)

substrate

plate

selective melting of skin

area

selective melting of core

area Deposition of “skin layer”

(50 μm)

SLM of skin area

Re-iteration until core layer

thickness is reached (e.g. 4

times if core layer thickness

is up to 200 μm)

SLM of core area

Repetition of steps 1 - 4

Procedure

Skin-Core Strategy

© Fraunhofer ILT

Material: Stainless steel Skin PL: 350 W Beam diameter: 200 µm Layer thickness: 50 µm

Core PL: 1000 W Beam diameter: 1000 µm Layer thickness: 200 µm

Skin-Core Strategy

© Fraunhofer ILT

Additive Manufacture of skin-core demonstrator

Tool insert for injection mold

Conformal cooling channels

Layer thickness ratio of 1:4

Skin core overlap 0.75 mm

Density ~ 100%

Core dep. rate: 16.8 mm³/s

Skin dep. rate: 3 mm³/s

Average dep. rate: 10.2 mm³/s

© Fraunhofer ILT

Commercial machine with 1kW laser system

© Fraunhofer ILT

Deposition rate Since 2003 :

Industrial state-of-the-art unchanged at approx. 1.2 mm³/s

Since beginning 2007: Increase in deposition rate up

to approx. 9 mm³/s (experimental set-up)

2008:

Installation of demonstration machine

2009: Further increase of deposition rate up to min. 12 mm³/s by using higher laser power (up to 1kW)

Deposition rate [mm³/s]

time

1997 2003 2006 2009 2000

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

…

2012

Actual Research Topics/ Productivity: Process speed

© Fraunhofer ILT

Selective Laser Melting SLM

SLM Machine

Process

© Fraunhofer ILT

Innovation Award of the federal state of North Rhine Westphalia 2011 Additive Manufacture by Selective Laser Melting SLM

Duesseldorf November 14, 2011

© Fraunhofer ILT

Content

Motivation

Process basics



© Fraunhofer ILT

Digital Photonic Production “From Bits to Photons to Atoms” Light is unique due to…

highest energy density

shortest pulses

highest speeds

massless, forceless and contactless

best controllability (CAD>Product)

© Fraunhofer ILT

Product complexity


Lot size


Cost Cost

Digital Photonic Production – “Production 2.0”

© Fraunhofer ILT

Product complexity


Lot size


Cost Cost




© Fraunhofer ILT

Product complexity


Lot size


Cost Cost


Individualisation for free Complexity for free



© Fraunhofer ILT

Product complexity


Lot size


Cost Cost


Individualisation for free Complexity for free

Innovative products



© Fraunhofer ILT

Product complexity


Lot size


Individualisation for free Individualisation for free Complexity for free

Innovative products

Cost Cost




© Fraunhofer ILT


Product complexity


Lot size



Innovative business models

Individualisation for free Individualisation for free Complexity for free

Innovative products

Cost Cost

Producer

Product

Providing-Value Value-Co-Creation

Producer Customer

Product

Environment


© Fraunhofer ILT

Individualization for free – Shapeways

Source: Shapeways

© Fraunhofer ILT

Shapeways – new kind of production community

Source: Shapeways

© Fraunhofer ILT

Shapeways – huge momentum for 3D printing in 2012

1,000,000 3D printed products in 2012 over 10,000 uploads per week 8000+ Shapeways Shops shop owners earned $500,000 in 2012 230,000+ Community Members in over 130 countries

new factory opened in New York

to 3D print 3 to 5 million unique products per year

Source: Shapeways

© Fraunhofer ILT

Nokia Lumia 820 3D printing community project – First major label released 3D Development Kit (3DK)

Source: Nokia

© Fraunhofer ILT

Direct Photonic Production LAM – A Paradigm Shift in Manufacture Topology optimized axle stub

with hollow structures – additively manufactured by Selective Laser Melting SLM

Engine block – additively manufactured (‚printed out‘) by Selective Laser Melting SLM

© Fraunhofer ILT

Additive Manufacturing – Process Chain

Finish Schlichten Drehen Design/

Function Additive

manufacture

Shaping

Measuring

Raw

material,

e.g. powder

Clamping CAx

Finishing Roughing Turning

Continuity/ Integration

Adaptive Automated Machining



100 µm

© Fraunhofer ILT

Opportunities and challenges in part design & simulation

Material: AlSi10Mg Weight saving: ca. 30 %

Bionic design Lattice structures Topology optimization

Top: 338 elements 13 min 13 s

Center: 21,000 elements 41 min 47 s

Bottom: 2,100,000 elements ca. 48 h

© Fraunhofer ILT

Vision – Lightest material of the world

Density: 0,9 mg/cm³

99,99 % air

100 times lighter than foamed polystyrene

1000 times thinner than human hair

Source: Nature, University of California Irvine

© Fraunhofer ILT

Opportunities and challenges in part design & simulation

Source: ASME Mechanical Engineering Magazine, Netfab

Vision I: Tailored part design (designed for function, only)

Individualized parts

Design tools - patient specific - part specific

Solution-Space-Design

Real time simulation

Functional parts

Design and simulation tools for - filigree structures - multi scale structures - multi material systems

© Fraunhofer ILT



Function Additive

manufacture

Shaping

Measuring

Raw

material,

e.g. powder

Clamping CAx






100 µm

© Fraunhofer ILT

Material development: Powder additives (Inconel 718)

TiN

inclusions

Micro

cracks

Powder O N Porosity Cracking Inclusions (TiN)

AMDRY 0.010 0.020 High Low Low

Nistelle 0.035 0.110 mid High High

TLS 0.013 0.009 Low Low Low

Now: Designed for APS, VPS, HVOF Thermal Spraying

Future: Tailored for AM

© Fraunhofer ILT



Function Additive

manufacture

Shaping

Measuring

Raw

material,

e.g. powder

Clamping CAx






100 µm

© Fraunhofer ILT

Process qualification for new material(s) combinations

Vision III: Tailored processes (inorganic & organic)

• For laser and non-laser based processes such as SLM, LMD, STL, FDM, EBM (ARCAM), LIFT (organic materials) etc.

• For non powder-based processes (wire, liquids, slurry etc.)

• Below 10 µm3 resolution (voxel) with materials:

• Industrial polymers (p-T-t cycles; e.g. via pressurized process chamber)

• Hybrid materials e.g. switchable properties through switchable materials (metal-polymer, MMCs, CMCs, particle reinforced,…)

• Organic materials such as biopolymers Aim: Tissue engineering & Printable organs (approach: LIFT processes)

© Fraunhofer ILT



Function Additive

manufacture

Shaping

Measuring

Raw

material,

e.g. powder

Clamping CAx






100 µm

Interfaces

© Fraunhofer ILT

Source: Fraunhofer IPT

Efficiency

Higher efficiency of

additive manufacturing

process

Parameters focusing on

optimum

of total process chain

Accuracy

Adaptive finishing step

provides

high part precision

Elimination of manual

rework reduces failure

sources

Design

(inner and outer)

geometry

Adaptive Finishing

Manual

rework Measuring

Correction strategy

Additive manuf. process

Holistic view on productivity and quality

Holistic view to ensure productivity and part quality

Vision IV: Tailored process and CAx

chain(s) (holistically adapted)

© Fraunhofer ILT

Internal

Perspective

External

Perspective

Pro

du

ct

Pe

rsp

ecti

ve

Pro

du

cti

on

Pe

rsp

ecti

ve

Product Program

I

Product range

Product Architecture

II

Inner structure of

the products

Production Structure

III

Resources and

processes

Supply Chain

IV

Logistic interface

to the customer


© Fraunhofer ILT

Explainability at the

Point of Sale


Flexibility

Fit o

f V

ariety

Resource Utilisation

Supply Chain Inventory Efficiency

Su

pp

ly C

hain

E

ffe

ctive

ne

ss

1

0

1

0

0

1

0

1 0 1 0

Product Program Product Architecture

Supply Chain Production Structure

II I

IV III

1

1

1 0 1 0

Pro

du

ct

Arc

hite

ctu

re

Co

mm

ona

lity

Optimization toward the

center reflects potential

for individualized

production

Pro

cess

Co

mm

ona

lity

Current operating

points of a

production system


© Fraunhofer ILT

Explainability at the

Point of Sale


Flexibility

Fit o

f V

ariety

Resource Utilization

Supply Chain Inventory Efficiency

Su

pp

ly C

hain

E

ffe

ctive

ne

ss

0

1

0

0

1

0

1 0 1 0

Product Program Product Architecture

Supply Chain Production Structure

II I

IV III

1

1

1 0 1 0

Pro

du

ct

Arc

hite

ctu

re

Co

mm

ona

lity

Pro

cess

Co

mm

ona

lity

Only the integrative

configuration within all

areas exploits the full

potential of DPP


© Fraunhofer ILT

“Advanced Manufacturing is the use of innovative technology to improve products or processes.” (http://en.wikipedia.org/wiki/Advanced_manufacturing as of November 22, 2013)

“Advanced Manufacturing is the use of innovative technology to improve products and processes.”

“Advanced Manufacturing is manufacture for design instead of design for manufacture.”

Mission statement

http://en.wikipedia.org/wiki/Advanced_manufacturing

http://en.wikipedia.org/wiki/Advanced_manufacturing

3D-Drucker/Generative Fertigung Wie sich die Produktion ... · © Fraunhofer ILT Static mechanical...

Documents

Transcript of 3D-Drucker/Generative Fertigung Wie sich die Produktion ... · © Fraunhofer ILT Static mechanical...