Additive Manufacturing and 3D Printing LENS® Technology

ADDITIVE MANUFACTURING OF METAL COMPONENTS CONFERENCE AT IK4-LORTEKNOV. 27 th, 2013

Presented by: Matej Balažic -Manager Engineering & Applications

© EFESTO LLC MI, USA

W: www.efesto.usE: info@efesto.us

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The LENS 3D printer can process a wide variety of metals including titanium, nickel-base super alloys, stainless steels and tool steels - all of which are commercially available in the required powder form. The results from LENS consistently demonstrate better metallurgical and mechanical properties than other processes due to an improved microstructure.

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Who is Efesto?

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Hephaestus, the God of Metallurgy, Sculpture, Engineering, Technology and Fire.

The name is derived from and inspired by EFESTO High energy enterprise focused on 3D Metal Printing Solutions Active in Europe, Asia Pacific, Russia, and Americas Very close business partnership with Optomec Inc. Global leader on industrializing Laser Metal Deposition (Blown Powder Laser Deposition)

technology and applications Visionary team of industry “thought leaders” & business professionals Modular systems, diverse applications in repair, hybrid manufacturing, Prototyping,

materials R&D Targeting all key industrial segments + academia Plan – Aggressive organic and acquisitive growth Plan – Dedicated repair/prototyping/service bureaus with joint venture partners Plan – Deliver more than 200 LMD standard and custom engineered systems by 2018 Primary Mission – Delight Its Customers!

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Efesto – Primary Focus and Markets

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INDUSTRIES – Truly Global Footprint Aviation Defense – Army, Navy, Air Force, R&D Oil and Gas/Energy Tooling/Die and Mould Academia – advanced R&D including Bio-Medical Mining and Construction Space (Launchers and Satellites) Automotive

APPLICATIONS – Value Addition to Conventional as well as to Additive Manufacturing MRO – maintenance, repair and overhaul Hybrid manufacturing, remanufacturing, redesign Gradient metals, multi-alloy, alloy discovery Prototyping – medium and large sizes Advanced materials R&D Education and training

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POSSIBLY THE LARGEST 3D PRINTED PARTS MADE TODAY

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Keep in mind, building such parts can cost > $ 100,000, and what if:

A mistake is made near the end of the process

A small feature needs to be changed once part is made

The part needs to be made of several dis-similar metals

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POSSIBLY THE LARGEST 3D PRINTED PARTS MADE TODAY

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Keep in mind, building such parts can cost > $ 100,000, and what if:

A mistake is made near the end of the process

A small feature needs to be changed once part is made

The part needs to be made of several dis-similar metals

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THIS COULD BE A REALITY TOMORROW

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Spain:

Efesto

represenatative

Slovenia:

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Slovenian LENS® Instalation (Optomec 850R)

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LENS® IN INDUSTRIALENVIRONMENT, DIFFERENT TOOL APPLICATIONS

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The LENS® Process Schematic

9“Courtesy Optomec Inc. All Rights Reserved”

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LENS® 450 System

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Standard LENS® 450 Features 100mm x 100mm x 100mm process work area 400W IPG Fiber Laser Class 1 laser enclosure, hermetically sealed 3 axis motion control X,Y,Z Single powder feeder CE Certification available

“Courtesy Optomec Inc. All Rights Reserved”

EDUCATION, R&D, SMALL FABRICATION/REPAIRS

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LENS® MR-7 System

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Standard LENS MR-7 Features 300mm x 300mm x 300mm process work area 500W IPG Fiber Laser Class 1 laser enclosure, hermetically sealed 3 axis motion control X,Y,Z Gas purification system maintains O2 < 10ppm Dual powder feeders with gradient capability 380 mm diameter ante chamber CE Certification available

“Courtesy Optomec Inc. All Rights Reserved”

R&D, MEDIUM SIZE FABRICATION/REPAIRS

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LENS® 850R System

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Standard LENS 850R Features 900mm x 1500mm x 900mm process work

area Class 1 laser enclosure, hermetically sealed 5 axis motion control X,Y,Z with tilt & rotate

table Gas purification system maintains O2 <

10ppm 2 powder feeders 380 mm ante chamber 1kW IPG Fiber Laser

“Courtesy Optomec Inc. All Rights Reserved”

LARGER FABRICATIONS/REPAIR,& HIGH POWER

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Product Description

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Near Net ShapeFully Functional!

3D CAD ModelConvert to STL fileTool path generation

Multi Nozzle Powder DeliveryMetal Powder melted by LaserLayer by layer part build/repairUp to 7 Axes range of motionClosed Loop ControlsControlled Atmosphere (<10ppm O2)

DESIGN LENS PROCESS PART

“Courtesy Optomec Inc. All Rights Reserved”

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Examples

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1. APU AND OTHER SYSTEM/ENGINE ACCESSORIES

2. JET ENGINE AND ITS SUBPARTS

3. FUSELAGE COMPONENTS

4. UNDERCARRIAGE

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Examples

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Repair Process used by MTU including Electron Beam Welding

Aerospace Tools for Hydroforming Produced in EMO/TIC-LENS; EADS A320 fuselage components

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ADVANTAGES AND APLICATIONS

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Advantages: Near Net Shape Thin Layers/Less Weld Clean-up Low Heat Input/less part distortion Automated process / Precision control Small heat effected zone/low dilution Simple Low Cost Tooling/Fixture Shorter remanufacturing time Cost saving

Applications: Blade tip repair and build-up Seal replacement and build-up Knife edge seals Unlimited alloys

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LENS® BENEFITS FOR REPAIR

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Less heat inputLess distortionLess propensity to crackExcellent density & adhesionMinimal effect on the componentPowder Fusion has better integrity than weldingLENS® allows re-commission of parts deemed

non-repairable via other processes.

“Courtesy of Optomec Inc. All Rights Reserved”

Small Heat Affected Zone (HAZ)

LENS® Deposit Weld Deposit

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LENS® AS PART OF MANUFACTURING PROCESS

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Side/contact surfaces of the Jet Engine Turbine Assembly have to provide bigger wear resistance which is achieved by Stellite 6 and Stellite 12 material.

Stellite material (4-5mm which wire) is manually welded to parts (T.I.G.)

To achieve final dimension and geometry tolerances parts have to be finished (grinded). Due to removal of a large hard material quantity, grinding wheels wear extensively.

LENS® technology has been introduced to provide greater Near Net Shape of cladded Stellite layers, faster machining times, lower manufacturing costs and higher level of the process automation.

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LENS® USE FOR REPAIR AIRFOILS

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Case Study: Ti Airfoil RepairTip RepairLeading Edge RepairSurface defect (scratch) repair

Time for Tip RepairSet-up and toolpath <1 minuteDeposition 30 seconds for 2.5mm tall repair

Tip Repair and Coating

Leading Edge Repair

Scratch Repair

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Free form Application – Critical Component Repair

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Effective and time-saving repair process of jet engine compressor parts (dented blades)

5th compressor stage blade (Ti 6-4),

10th compressor stage (Inconel 718).

Reduce repair times up to 50%* Reduced repair costs up to 30%* Total costs of repair regarding to

new part price: 13% Ti 6-4 (300 EUR new part / 40

EUR LENS® repair) 42% Inconel 718 (200 EUR new part /

80 EUR LENS® repair)*(regarding to wire surface welding process)

LENS® system from Optomec Ti and Ni (Inconel) powder

material of adequate quality

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General Electrics CF34-3B1

Dented Blades

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Material Structure

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CAD model5th stage blade

LENS® claddingTi6-4 powder

Material structureLENS® cladded layers

Material structureLENS® cladded layers

Material structure-coreLENS® cladding Inconel 718 powder

CAD model10th stage blade

Material structure-core

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CERTIFICATION PROCESS

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In order to use specific Repair or Manufacture Process all needed approvals has to be given by Engine/Aircraft Manufacturer and appropriate State Authority.

Engine/Aircraft Manufacturer has to evaluate proposed technology with its internal standards. This can lasts from few months in case of simple parts/components till few years in case of “important“ components.

Some Repair work of non-flying components can be done by authorized MRO (Maintenance and Repair Organization) without approval of the Manufacturer.

Efesto/Balmar has established strong relations with Engine/Aircraft Manufacturers and regional MROs worldwide in order to support them at LENS® technology implementation.

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REPAIR AND MAINTENANCE IN JET ENGINE SECTION-MRO

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Engine Casing/Surface Forms Repair

Disk Surface Wear RepairBlades Repair and Surface Improvement

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THE LENS® PROCESS – PROTOTYPING OF NOVEL DESIGN

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Bell Helicopter Mixer (Ti-6-4)9 weeks “classic manufacture“; LENS® 3 weeksRapid Prototype (Fully Functional)Unmanned Combat Armed Rotorcraft (UCAR)

“Courtesy of Optomec Inc. All Rights Reserved”

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LENS® Application Examples

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Ti 6-4 Dual Wall Duct – JSF EngineProof-of-Concept LENS® Article10 cm Dia. Base, 25 cm Dia. Top x 10 cm Tall

“Courtesy of Optomec Inc. All Rights Reserved”

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Inconel Freeform Build – Too large to build in most contemporary SLM/SLS machines

“Courtesy of RPM Innovations Inc. All Rights Reserved” 28

Inconel Laser Freeform 24 tall x 24” long

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Inconel Freeform Build – too large to build in most contemporary SLM/SLS machines

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Inconel 625 Freeform approximately 17” OD.

“Courtesy of RPM Innovations Inc. All Rights Reserved”

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SOME FACTS ABOUT SPACE PRODUCTS

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To send 1kg of Space Vehicle or Satellite or any other product into Orbit it costs 10.000 USD $ To send 1kg of Space Vehicle or Satellite or any other product to the Moon it costs 100.000

USD $ (x 10) To send 1kg of Space Vehicle or Satellite or any other product to the Mars or any other near

planet it would cost 1kg = 1kg of Diamonds. International Space Station (ISS) weights 450.000 kg For all space applications it is known 1 EUR investment brings back 7 EUR benefit.

Weight of Space Products is very important. Reduction of weight at same performance characteristics can be achieved by AM technologies like LENS® technology.

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From Invention to Product Innovation

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USAGE OF LENS® FOR SPACE APPLICATIONS

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Direct from CAD to part – no tooling required Superior material properties – full functionality (Novel Microstructures) Near-net-shape build or repair – minimal finishing Single-step process – reduced time and cost (Time Compression) Low heat input – low distortion and heat-affected-zone Closed loop for precision deposition control High efficiency lasers for reduced cost of ownership Novel 3D Shapes Functional Gradients Simplified Supply Chain Manufacturing Agility High level of Technology Readiness

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SPACE APPLICATIONS - Satellite structures, solar panels, on-ground equipment

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Design, development, manufacturing and qualification of high performance satellite structures (good volume/weight ratio),

Introduction of Function-gradient metal materials and shape effect into the structure, Light and high performance solar panels housing, Advanced method of metal elements joining

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Prototyping and Manufacture of Specials Components for Satellites

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Joint Elements

Support Elements for Solar Panels

Thruster Nozzles

Support Elements for Antennas

Satellite Housing

Housing Panels

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SPACE APPLICATIONS - Satellite structures, solar panels, on-ground equipment

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Advanced Nozzles shapes for exhaust systems (rocket engine), Advanced cooling channels for rocket engine, Prototyping of advanced rotor (impeller) for cooling liquid in the rocket engine, Introduction of Function-gradient metal materials and shape effect into the launcher

structure, Reducing weight of the launcher for 20% or more, Effective and advanced repair of existent space vehicles and launchers, Introduction of special additional protective coatings for the structure Prototyping of novel elements with laser manufacturing technology supports new concepts of

space vehicles and engine propulsions.

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Development, Prototyping and Manufacture of Specials Components for Space Launchers

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Nozzle Elements

Elements for Propulsion System

Light weight Structures: Diffusion Bonded Titanium Honeycomb

Turbine Blades

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TOPICS THAT WE ARE INTERESTED IN

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Space technology Critical technology Space robotics Satellite technology Launcher In Space propulsion Small scale satellitesSatellite Communication Satellite manufacturingSpace Exploration Propulsion system Protection systems (thermal, radiation)

Targeted field of cooperation Development, prototyping and

manufacture of special components for satellites and space launchers,

Production of component prototypes with LENS® technology with parallel technology development and optimization,

Laser welding of components for satellites and space launchers,

Final machining of prototypes and components.

Reference in Space projects:

ESA/PECS Programme (2011-2014): Project title: Development, Prototyping and Manufacture of special Metal Components for Space Applications with Advanced Laser Technology LENS® (LENS® FOR SPACE)

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LENS® APPLICATION – M1ABRAMS TURBINE COMPONENT REPAIR

40Courtesy Anniston Army Depot

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LENS® APPLICATION – M1ABRAMS TURBINE COMPONENT REPAIR

41Courtesy Anniston Depot Army

Repair Facts: Material: IN718 Engine: AGT1500 LENS® Process Advantages: Properties, Low Heat Input, Near Net Shape In Production at Anniston Army Depot, $5M saved in first year

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Labyrinth Seal (Air Seal Restoration)

42“Courtesy Optomec Inc. All Rights Reserved”

Undersized Air Seals

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Labyrinth Seal (Air Seal Restoration)

43“Courtesy Optomec Inc. All Rights Reserved”

Pre- Machine

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Labyrinth Seal (Air Seal Restoration)

44“Courtesy Optomec Inc. All Rights Reserved”

LENS® Build-Up

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Labyrinth Seal (Air Seal Restoration)

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LENS® Procedure:Pre-machine undersized air seals.LENS® Build-Up utilizing Inconel

718 material.Vacuum heat-treat (Aging).Final machine.Non-Destructive Testing

LENS® Cycle Time: 60 minutes per part

“Courtesy Optomec Inc. All Rights Reserved”

Finished Machined

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LENS® Application Examples – MR7 in container)

46“Courtesy Optomec Inc. All Rights Reserved”

The Mobile Parts Hospital (MPH) is a compact communications and manufacturing unit. It is designed for deployment to remote locations for emergency repair of non-operational equipment. A combination of advanced technologies enables the MPH to quickly and efficiently produce new parts or repair parts on demand.

ISO CONTAINER - DEPLOYED BY LAND, SEA OR AIR

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Ti-6Al-4V Feature Addition To A New Forging

47“Courtesy RPM Innovations Inc. All Rights Reserved”

Ti-6Al-4V Boss Added

Ti-6Al-4V atomizer wheel.

Ti-6Al-4V bosses are Laser Free Form Manufactured To reduce forging thickness and machining costs.

Ti-6Al-4V Boss Added

Final Machined Atomizer Wheel

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Industrial Applications: Feature Addition

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Hybrid Manufacturing gives Time Compression & 30% Cost Reduction

Tough to cast, long lead time: 52 weeks to cast Hybrid route: machined disk with details added by LENS® process Delivery Time: 3 Weeks. Superior Design: reduced weight Design changes implemented during development

“Courtesy Sandia National Laboratories. All Rights Reserved”

Electronics Housing in 310SS

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Dual Thin Wall Cooling Channel Test Part

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IN625 Freeform Dual Wall Cooling Channel a = 0.065” b = 0.065” c = 0.180” Approximately 0.06” Wall Thickness

Final Deposition Final Deposition

10.5” a b c

Channel Dimensions

“Courtesy Optomec Inc. All Rights Reserved”

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Ti-6Al-4V Freeform Geometry Capabilities (too large to build in SLM/SLS)

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Ti-6Al-4V Laser Freeform 28 inch tallThe part shows internal piping various overhangs along with tying in walls to one another

“Courtesy of RPM Innovations Inc. All Rights Reserved”

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ECS Duct Example

“Courtesy of RPM Innovations Inc. All Rights Reserved” 51

Ti-6Al-4V ECS Duct PrototypeUtilizing Free Form Manufacturing Drastically Reduces Welds per Conventional Techniques

Multi Axis LaserFree Form Manufacturing

Finished Part

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"Today EFESTO will do what others won't, so that tomorrow our customers can do what others can't"