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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
1
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
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
Cold Spray
Deposition
EB
EBFF Wire Electron Beam
Electron Beam Free Form
TIG/L
Hot Wire Wire TIG/ Laser
MIM/SNS HIP
Consolidation
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
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
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
Deliverables
Material understanding & use guidelines
Development Processing & robustness
Specifications
Physical & mechanical properties
Environmental evaluation
Maturation
Component suitability
14
8
GE Proprietary Information
Qualify Explicit Controls on Machine, Material, and Process
(Examples shown, not an all inclusive list)
Stress Capability
Powder Size Laser Power
Powder Composition Laser Travel Speed
Powder Reuse Procedures Laser Dwell Time
Qualification Inspection
Machine Material Process Part Non-Destructive Destructive
Functional
CT/VCT/CMM Part Specimen
Checks
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
15
1
GE Proprietary Information
Supporting Industry Initiatives
Specifications Industry Groups
15
2
GE Proprietary Information
Supply chain shift in progress
Apply at www.geadditive.com