1

GKN Aerospace Additive Manufacturing Rob Sharman – Head of Metallics Technology

Societe Generale 2014

2

Additive Manufacturing Terminology

The ASTM definition:

“The process of joining materials to make objects from 3D model

data, usually layer upon layer, as opposed to subtractive

manufacturing methodologies, such as traditional machining”

EBM EBFFF

3D-Printing SLS

SLM D

MD

DM

LS

FDM ALM

SLA

LENS

LD

W

WAALM

Polyjet

LC

3

High geometric complexity enables next generation small prismatic components. Accurate but near-net

parts and claddings

High material fusion rate and deposition technique enable large scale near-net shape parts or grow-outs

Deposition of powder fused using laser in a chamber to produce

part

LASER

(POWDER)

Free deposition of wire fused using

plasma arc to produce part

PLASMA

(WIRE)

Deposition of wire fused using electron or laser beam in a chamber to produce

part

EB

(WIRE)

LASER

(WIRE)

Laser or electron beam selectively fuses powder on a bed in a chamber to produce part

LASER

(POWDER)

EB

(POWDER)

PICTURE

DESCRIPTION

APPLICATIONS

DEPOSITION POWDER BED

DESIGNATED ICON

Powder / binder system requiring

down-stream consolidation

BINDER

(POWDER)

Net-shape parts achievable at

automotive rates

Additive Manufacturing

Fraunhoffer ILT

Arcam

TWI

Cranfield

University

GKN Aerospace Höganäs Digital Metal®

TWI

GKN

Aerospace GKN Aerospace

Cranfield University

Cranfield

University

SMALL PUDDLE DEPOSITION

• Lower material throughput deposition systems

• Focus on Ti and Ni alloys

• Nearer net-shape add-ons and prismatic pre-forms

• Engine component fabrication, component repair and grow-outs (cost & performance)

• Broad range of medium-size engine and structures components; fabrications

LASER P/BED

• Lowest material thru-put

• Ti, Ni and steel alloys

• Nearest-net

• Intricate hi-value components

• Engine parts and small inserts

EB P/BED

• Low material thru-put

• Ti6Al4V

• Highly net-shape

• Small – medium prismatics

• Structural brackets, engine parts and fabrications

INDIRECT P/BED

• Low material thru-put

• Cast-able alloys

• Highly net-shape

• Complex castings and inserts

•Engine parts and fabrications

LARGE PUDDLE DEPOSITION

• High material throughput deposition systems

• Focus on Ti

• Large-scale pre-forms

• Initial cost-driven introduction

• Applications including large aero structure components

EB P L L L EB B

Virginia Tech

GKN

Aerospace

Fraunhoffer ILT

Sciaky

Reis

Robotics

4

History & Lifecycle of Technology Adoption

Composites

1930 1950 1940 1970 1960 1980

NC Machine

Invented

Robotic

process

reaches

manufacturing

maturity

Applied

across

multiple

industries

Fiberglass

Patented

Carbon Fiber

production

begins

All fiberglass

aircraft;

H-301

Dragonfly

CNC Machining (Subtractive)

Over 40 Years!

Over 40 Years!

2000 1990 2010

787

commercial

aircraft first

flight

Metallic AM

Entire history of AM!

Gartner Hype Cycle

5

Ti Growth in Airframe Applications

Growth in use of Ti in Aerostructures

Of particular note in recent years has been the rapid growth of Ti and its alloys in airframe

applications

This has been predominately linked to the growth in CFRP due to the better compatibility of

Ti alloys (galvanic corrosion and thermal expansion) with CFRP

6

AM within Processing Portfolio

AM ONLY

Delivery Drivers Cost Drivers Performance Drivers

AM IN COMPETITION WITH OTHER TECH

L EB

Powder Bed Deposition

L EB P L

DEPOSITION

POWDER BED

DEPOSITION

Norsk Titanium EADS GKN

Data Release DfM

Complete

Tooling Ready

1st Article Production

< 95 WEEKS

< 12 WEEKS AM

Conventional

7

AM Adoption

Cost Reduction - Aero

Niche/High Performance - Aero & Auto

Near net pre-forms Added features Improved functionality/performance

1

Introduction of both new materials and processes is challenging

Conservatism and healthy cautiousness are barriers to initiatives

Step-wise approach is implicitly required

“INITIAL” phase

Generally cost-driven implementation

Allows both GKN and customer (and supply chain) to acquaint

themselves with challenges and opportunities

“NEXT” phase

Builds on “INITIAL” phase

Allows all parties to fully exploit AM technology benefits

PR

IMA

RY

S

EC

ON

DA

RY

DERIVATIVE SIMILAR NEW

8

Generic Conventional Component

9

Generic Conventional Component

Mat’l = 4.85kg

Swarf = 4.08kg

Mat’l = 1.08kg

Swarf = 0.31kg

Part = 0.77kg

Machining Route to Man’f AM Route to Man’f

10

Generic Conventional Component

~5 x less feed stock

~13 x less swarf

Conventional design (not yet

optimised for weight)

11

The possibilities and benefits are exciting

Unlocks Materials Science

Only uses the material you need - uses less material

Design no longer constrained by conventional manufacturing processes

Allows design for functionality

Speed and flexibility of development

A revolutionary set of technologies – not evolutionary

Phased introduction is implicitly required

Secondary derivative structure before primary optimised

Need to pin variables to gain acceptance

Process and material are now linked like never before

Big challenge to the industry in evaluation

How to certify

New and novel QA techniques required

AM Current R&D Programmes GKN Additive Manufacturing

12

GKN Investment and Growth in Additive Manufacturing

GKN sees additive manufacturing as a high priority technology

GKN is investing and expanding our portfolio in AM across the business,

leveraging our expertise across divisions

GKN is expanding and establishing new Centres of Excellence in additive

manufacturing, building on existing capability to build a global network:

Powder bed - Filton (UK)

High rate Deposition - St Louis (USA)

Fine Deposition - Trollhatten (Sweden)

Materials - New Jersey (USA)

Operating across the whole value chain, from raw material, design, process

and application

Partnered with key academic institutions, customers and suppliers

Understand the criticality and potential of design, and GKN is developing the

skills and design toolbox to take advantage of the disruptive nature of additive

manufacturing