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Additive Manufacturing Material

Implementation at GE
GE Additive
10 August, 2017
Confidential. Not to be copied, distributed, or reproduced without prior approval.
What is Additive Manufacturing (a.k.a. 3D
Printing)
3D printing or additive

waste
manufacturing (AM)
is any of various processes for making
a three-dimensional object of almost
Additive Subtractive any shape from a 3D model or other
(Traditional)
electronic data source primarily
through additive processes in which
successive layers of material are laid
down under computer control.
- Wikipedia
Successive layers of material are laid down

133
DMLM (Direct Metal Laser Melting) Basic Process
Map Post
Thermal
AM Process Processing/
Processing
Inspection

3D CAD Model Final Part

Prep for Process

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3
4
GEs advancement in additive so far Advanced Turboprop
Prelim design

A-CT7 Engine
LEAP Fuel Nozzle Bigger Parts
FAA Certified
Technology

Rotating Parts
Power F-Class Flex
Tip Oil & Gas
GE90 engine
Nova LT Bigger Systems
Swirler
T25 Sensor
FAA Certified Multi Modalities
1st LEAP Fuel Nozzle 1st Heat Exchanger

16+ years of
Additive Science
2010 2011 2012 2013 2014 2015 2016 2017

Formation of GE
Infrastructure

Aviation additive team


Acquisition of GE Additive
Morris Expansion
Technologies
GE Aviation
Additive Technology Center Customer
(ATC) opens Experience Centers

GEs Center for Additive


Technology Advancement
(CATA) opens

Acquisition of
Concept Laser GmbH (75%)
Arcam AB (76%)
It started with one part
Capabilities of full production
35,000 40,000 per year 20 1
PARTS

25%
WEIGHT
REDUCTION 5x DURABLE
MORE

GE Confidential Information

GE Proprietary Information
LEAP is a trademark of CFM International, a 50/50 JV between GE and Safran Aircraft Engines
2017 General Electric Company - All rights reserved
Additive value proposition LEAP fuel nozzle actuals
Traditional TAPS Fuel Nozzle LEAP DMLM Fuel Nozzle
100%

0%
Inventory Life Cycle Cost Mfg Cost Part Weight
Advanced turboprop engine (ATP)
Combustor test schedule reduced from 12 WEIGHT
months to 6 months REDUCTION

LOWER MISSION
FUEL BURN

PARTS
2017 General Electric Company - All rights reserved
Modalities and Materials

Confidential. Not to be copied, distributed, or reproduced without prior approval.


2017 General Electric Company - All rights reserved
Available metal additive options
Process Form Heat Source Speed Precis Size
L
Powder Bed
DMLM Powder Bed Laser
Direct Metal Laser Melting
EB
EBM Powder Bed Electron Beam
Electron Beam Melting
L
LPF Powder Deposition Laser
Laser Powder Forming

Cold Spray
Deposition

Powder Deposition Momentum

EB
EBFF Wire Electron Beam
Electron Beam Free Form
TIG/L
Hot Wire Wire TIG/ Laser

MIM/SNS HIP
Consolidation

Binder Injection Consolidation


Metal Injection Molding

Binder Jet Binder Jet Consolidation


Concept Laser and ARCAM Products

Mline
Mlab

Q10
Q20

A2
M2
Xline
Typical DMLM to EBM comparison
Direct Metal
Electron Beam Melting
Laser Melting
100-1000 W 3000 W
Energy Source
Fiber Laser Electron Beam
Scanning Method Optical Mirrors Magnetic Deflection
Build Layers 20 to 50 m 50 to 70 m
Accuracy 50 m 200 m
Build Rate 13 cm3hr-1 55 cm3hr-1
Surface Finish 100-300 -in 800-1000 -in
Residual Stress High Low

GE Proprietary Information
2017 General Electric Company - All rights reserved
Currently available materials
Inco Inco SS
A205
Standard Alloys Available: 718 625 316L

Cobalt Chromium 17-4 SS


MS-1 F357
Inconel 718, 625 PH 15-5

Titanium 6AlV4 ELI, CP Ti Grade 2 AlSi10


Cu W HS188
Aluminum (AlSi10Mg, AlSi12) Mg

Stainless 316L(1.4404), 17-4PH 6061 Rene


CoCr HastX
Maraging Steel MS-1 (1.2709) T6 80
Bronze
Ti Ti 64 TiAl
Many more materials currently in development 6242

GE Proprietary Information
Material properties drive applications 210
YS (ksi) UTS (ksi)

200

190
AMS
180

170

160

150 AMS
140
DMLS
DMLM -- VV DMLS
DMLM -- H
H Wrought Low Wrought High

Elongation (%) Hardness (HRC)


50.0

40.0

AMS
30.0

20.0

10.0
AMS

0.0
DMLS -- VV
DMLM DMLS
DMLM -- H
H Wrought Low Wrought
High

GE Proprietary Information
Qualification & Inspection

Confidential. Not to be copied, distributed, or reproduced without prior approval.


2017 General Electric Company - All rights reserved
Safety
is priority #
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Additive Component Roadmap
Additive opportunities based on value
Identify Durability, fuel burn, emissions, weight, cost, new and innovative functions

Machine, material, and process development


Mature Process including machining / finishing, process monitoring, and inspection

To established additive design practices and lessons learned


Design Taking full advantage of geometrical freedom and material enhancements

Establish machine, material, process, and design requirements


Qualify Demonstrate all requirements are met or exceeded; lock processes

To performance level component, system, and engine requirements


Validate Coupling advanced analytics and testing

Component level testing as required (14 CFR Part 33 Section 33.91)


Certify Engine level certification (14 CFR Part 33 & 34)
Mature Additive Materials Development Process
Process Content
Concept Microstructural evaluation & heat treatment development
Process optimization / producibility
Mechanical properties & design curves / allowables
Environmental evaluation (fluids, corrodants, temperature/time, etc)
Feasibility Effects of subsequent processing / operation

Deliverables
Material understanding & use guidelines
Development Processing & robustness
Specifications
Physical & mechanical properties
Environmental evaluation
Maturation
Component suitability

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GE Proprietary Information
Qualify Explicit Controls on Machine, Material, and Process
(Examples shown, not an all inclusive list)

Powder Spec Laser Param


Powder Source Spot Size

Stress Capability
Powder Size Laser Power
Powder Composition Laser Travel Speed
Powder Reuse Procedures Laser Dwell Time

Calib & Maint Hatch Strategy


Preventative Maintenance Contour Pass
Pre-build Calibration Sky Writing
Factory Environ Controls Line Spacing or Boundary Overlap
Cycles to Failure

Post Processing Recoat Param


Mechanical Finishing Layer Thickness Contour
Thermal Exposure Recoater Arm Material
Recoater Arm Design
Hatch
Therm Proc Build Cham
HIP Cycle Parameters Build Atmosphere
Heat Treat/Solution Atmos Purge Gas
Braze HT Parameters Airflow
Solution Temperature Preheat Temp
Interpass Temp
Laser Parameters 14
9
GE Proprietary Information
Validate
Inspection and Quality Touch Points

Qualification Inspection
Machine Material Process Part Non-Destructive Destructive

Functional
CT/VCT/CMM Part Specimen
Checks

Proof Grain Size


Fuel Flow On-going
Defect Pressure Porosity
Dimensional Airflow Cut-Ups Material
Recognition Ultimate Surface
Other Testing
Test Finish

15
0
GE Proprietary Information
Validate
In-situ Inspection, Modeling, and Analytics

d Computational Meltpool
Materials Process
Engineering Monitoring

Faster
Material Development
Process Qualification Analytics
Part Certification

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1
GE Proprietary Information
Supporting Industry Initiatives
Specifications Industry Groups

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GE Proprietary Information
Supply chain shift in progress

2017 General Electric Company - All rights reserved


Investing in a limitless future
PRIMARY AND SECONDARY SCHOOLS (ages 8-16)
$2 million for 3D-printing equipment and curriculum
Focus on STEM/STEAM programs

COLLEGES AND UNIVERSITIES (2- and 4-Year)


$8 million for metal additive manufacturing
equipment
Focus on additive learning efforts

Apply at www.geadditive.com

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