Additive Manufacturing at GE Mohammad Ehteshami VP & GM, GE Additive

August 29, 2017

Capabilities of full production 35,000 – 40,000 per year

PARTS

DURABLE MORE

WEIGHT

LEAP is a trademark of CFM International, a 50/50 JV between GE and Safran Aircraft Engines

It started with 1 part …

25%

20 1

5x

REDUCTION

2

Then a system … Advanced Turboprop

PARTS

WEIGHT REDUCTION

Combustor test schedule reduced from 12 months to 6 months

LOWER FUEL BURN

20 %

5 %

855 12

At an enterprise level Design Manufacturing Services

Additive

1 Digital Twin

6-8 Engineers

1 Mfg. sources

Inspection Sys. &

Component to Repair

1 1 data lake

…powering

300 parts

60 Engineers 5

Conventional

40 data systems

Mfg. sources 50+

Turbine frame

Same frame

Repair Sources

• HQ in Lichtenfels, Germany

• 400+ employees

• Products: • Metal additive machines (Laser technology)

• Industries served: Aerospace, Medical/Dental, Auto, Jewellery

• HQ in Mölndal, Sweden

• 340+employees

• Products: • Metal additive machines (Electron Beam technology) • Materials (from AP&C) • Additive Service Bureau for Medical Industry (DTI)

• Industries served: Aerospace, Medical, Auto, Tooling

GE Additive

Focused on three

main offerings:

• Materials

• Machines

• Engineering Consultancy Services

Today…

• 1100 employees

• 22 sites

• Stakes in Concept Laser & Arcam AB

1

Machine Qualification

Qualification … and then fixed process control

Material Qualification … must buy-into material allowable curves, must meet material specs

Part Qualification … process must be in control, dimensional, functional

Part Inspection … methods based on traditional castings (gage, white light, FPI, X-Ray, CT)

Every Machine is a “Micro” Foundry

2

Certification: Material Qualification

Process Structure Properties

As-Built Structure

Isotropic Structure After Thermal Processing

Physical properties

Strength properties (static, fatigue)

Damage Tolerance

Variation (Lots, machines, etc)

X, Y, & Z Build direction

Surface finish factor

Part feature factor (e.g. thin wall)

Cycles to Failure

Alt

Str

ess

Machined

As-built surface

Powder specification

Machine parameters

Build chamber environment

Machine calibration

Thermal processing

Post processing

Powder re-use

Expanding Materials Capability

Inco 718

Inco 625

SS 316L

17-4 PH

SS 15-5

MS-1

Bronze AlSi10Mg

6061 T6

CoCr Hast X

Ti 6242 Ti 64

W

TiAl

A205

F357

HS188

Rene 80

Material allowables identified (GE Redbook design data)

Process/Part/System Validation

Fuel Nozzle Example

9

TIME AT TEMP

RIG TESTING

NOZZLES TESTED

CERT TESTING

PREDICTED LIFE

COMPONENT TESTING DESIGN ALLOWABLE

low cycle fatigue test 1-cup coking rig LEAP-1A Icing test

DIMENSIONAL

FEATURE DEBIT

9x 100% 500+

Powder Specification DMLM Process Specification

Chemical composition

Melting and atomization method

Powder quality

Process control

Particle size distribution (PSD)

Component Specification

Additive Specification Control

Fixed Process Controls

Equipment qualification & Preventative Maintenance

Power level verification

Facility environmental controls

Powder handling and reuse

Software control

Operator training

Record keeping

Machine restarts

Chemistry & Composition

Structure/ Porosity

Properties

Surface finish

Thermal processing

Proprietary specs evolving to industry wide specs

Building Industry Capability

Specifications Industry Groups

Accelerating the Additive Revolution

We’re focused in three areas…

Materials

Engineering

Machines +

Customer Collaboration

• Application Engineering • Rapid Prototyping • Low Rate Manufacturing

Customer Support

• Field Support • Spare Parts • Materials • Logistics

Customer Training

• Additive Design • Additive Machines • Additive Materials

GE Additive Customer Experience Centers

Our Customer Experience Centers are designed to help customers

understand the additive process; from design to prototyping to production and support them along the way

Pittsburgh Munich More coming soon…

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

• Over 400 recipients in 2017

COLLEGES AND UNIVERSITIES (2 and 4-Year)

• $8 million for metal additive manufacturing equipment

• Focus on additive learning efforts

• 8 recipients in 2017