Metal Additive Manufacturing KSB AM Consulting and ...
Transcript of Metal Additive Manufacturing KSB AM Consulting and ...
© Copyright KSB SE & Co. KGaA 2021
Metal Additive ManufacturingKSB AM Consulting and Manufacturing: Support for the Nuclear Industry to gain the benefits of Metal AMChristine Burow August 25, 2021
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Outline
1. KSB Group and Additive Manufacturing (AM)
2. Additive manufacturing examples
3. Quality Assurance for additive manufacturing
I AM @ KSB I August 2021 I
KSB Group 15,600 employees 100+ countries Sales revenue 2019
€ 2,400 million
1. One of the leading global producers of pumps, valves, motors and related service offerings, for nuclear industry and many other industries
2. Expertise in metal additive manufacturing
• For internal product development and production
• For external clients for any application
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Outline
1. KSB Group
2. Additive manufacturing examples
3. Quality Assurance for additive manufacturing
I AM @ KSB I August 2021 I
How can adoption of additive manufacturing be accelerated?
- Wait or start? Our experience is sooner the start, sooner and greater benefits
- AM will continually evolve, when is it ready enough?
- AM is an additional tool, not a replacement for conventional
- Need experience with AM to be widespread within the organization and across organizations
- Overcome inertia
- Study, but then try a part, learn and repeat
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BENEFITS of additive
manufacturing
INERTIA from the existing
systems, procedures and
approaches
What to do?
Watch and wait for everything to
be ‘done’
Start
Interest in AM
AM business case:48-hour impeller
Challenge: • Nuclear power plant needed
an impeller urgently
Solution: • AM part delivered in 48 hours
AM quality management process already in place
CAD designed, printed by LPBF, machined, tested and delivered
Benefit• Traditional manufacturing
would have taken much longer and cost much more
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Challenge• Framatome wanted to leverage additive manufacturing for
fuel assembly components with complex geometries for fuel assembly program
• How to source components that meet their high-quality standard requirements
Solution• Close partnership with KSB to develop program to qualify
AM part suppliers• They will qualify KSB AM department as an approved
supplier for Framatome’s fuel assembly parts by LPBF
Benefits• With quality assurance program in place, Framatome can
confidently gain the performance benefits of complex designs, which can only be cost-effectively produced by additive manufacturing
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AM business case:Reduced manufacturing cost for complex geometry Fuel assembly components
Upper tie plate grid
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Additive Manufacturing for Fuel Pump Development
Additive manufacturing:• Design phase: product development – samples for testing design concepts• Testing phase: prototype production• Manufacturing: each component will be assessed for optimal manufacturing strategy - AM
will be considered alongside forging and casting• Manufacturing considerations: materials, design complexity, specs, standards, …
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Chemical industry exampleImportance of close cooperation with customers
Development of partnerships
Testing of LPBF impeller in comparison with cast impeller at BASF, Ludwigshafen
Successful multi-year field test
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AM business case:Cost saving from complexity
conventional housing with welded cooling jacket topology optimized design (CAD: Siemens NX)
production tolerances with offsets for areas tobe machined (red)
fully assembled pump
Challenge: • European chemical plant
needed a more efficient pump for a high temperature acid application
Solution: • AM can produce parts with
complexity not possible with other manufacturing processes
• Design for additive: Topologyoptimized spiral pump housing
• Pressure boundary part
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Chemical plant customerbenefits with new pump housing:
• stiffness enhanced with exo-skeleton
• optimized flow of force
• weight-optimization: 57 %(30 kg → 13 kg)
• all-over cooling / heating
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Photos: Additively manuctured pump housing with integrated cooling
Designed for additive manufacturing: New and betterperforming design which cannot be casted
Pump housing printed in one piece on a laser powderbed powder fusion machine at KSB‘s additive manufacturing centre in Pegnitz, Germany
Developed in partnership with the customer
Pumped installed at a chemical plant in Europe
AM business case:Cost saving from complexity
I AM @ KSB I August 2021 I
machined machined
additive manufactured (SLM)additive manufactured (SLM)
AM business case:Cost saving from AM serial production
Challenge: • KSB was externally sourcing a
316L machined part, a mechanical seal flush connection
• Needed a lower cost part without compromising quality
Solution: • AM can produce quality parts
for serial production at a lower cost
• Weight reduced 208g to 130g• 84% cost savings
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Mechanical seal flush connection 92 parts per build job on
the EOS 400-4 Produced in-house with
84% costs savings Several 100 parts / year
AM business case:Cost saving from AM serial production
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Outline
1. KSB Group
2. Additive manufacturing examples
3. Quality Assurance for Additive Manufacturing
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Process chain for Laser Powder BedFusion (LPBF)
Managing the completeprocess chain is critical
Additive manufacturingprocess is „only“ one part ofthe complete process chain
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pre-process
in-process
post-process
componentdesign
CAD design, topology
stress analysis
life and CFD analysis
partpositioning
supportstructures
datapreparation
QM, certificates
cleaning, depowdering
heattreatment
cutting partsfrom plate
blasting, polishing, etc.
machining, etc.
AM process
machine setup
powderpreparation powder
required specs
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KSB Quality Assurance Program
• Part testing is critical and is complemented by: Comprehensive internal quality
program that covers every step from powder to post-processing
In-house testing and expertise Participating in standards
development and being ready to comply
Certification by TÜV Süd for pressure boundary parts
Long-term stable operation with ongoing testing to assure performance and resolve any performance deviations quickly
KSB Quality Assurance
for AdditivelyManufactured
Parts
Part testing: A. Non-
destructive testsB. Coupons for
destructivetesting
Comprehensiveinternal quality
program
In-house analytical testinglab – ISO 17025
Standards:ISO, ASTM, ASME, API, CSA, etc.
Certification for pressure parts
by AM fromTÜV Süd
Long-term stable operation
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KSB first to achievecertification for pressure boundaryparts, 1.4404 (316L)
Certification process by TÜV Süd:• Company• Material• Machine• Print location on the build
platform• Print orientation• Print parameters• Test coupons for destructive
verification• …https://www.tuvsud.com/en/press-and-media/2019/august/tuv-sud-issues-first-ever-certificate-for-additive-manufacturing-of-materials
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End-users are assured of AM part safety
Pressure equipment must comply with the requirements of QM
system in line with the EU Pressure Equipment
Directive 2014/68/EU
TÜV Süd provides testing, certification, auditing and advisory services, including ASME code services for nuclear www.tuvsud.com I AM @ KSB I August 2021 I
Quality Assurance Material testingin KSB’s ISO 17025 certified lab
• Test coupons across entire build chamber Mechanical and
chemical tests to demonstrate uniformity, including densities> 99,8%
• Routine testing to maintain long-term statistics to ensure stable operation
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- 552 551 551 554
546 552 549 554 554
551 557 559 558 552
549 552 555 553 553
550 550 555 554 -Example: Test coupons across build chamberTensile strength Rm /MPa
condition RP0,2/MPa
Rm /MPa AS /% KV /J
KSB Noribeam® 316L additive >275 >515 >40 >60
DIN EN 10088-3 wrought >200 500-700 >30 >60
DIN EN 10213 cast - 440-640 >30 >60
ASTM A479 wrought >170 >485 >30 -
ASTM F3184 additive >205 >515 >30 -
0
100
200
300
400
500
600
Rpo,
2 /M
Pa
Yield strength Rp0,2solution annealed
0°
45°
90°
2016 2017 2018 20202019
Example: Long-term data
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Materials qualityAlloy 625
• Material Data Sheet: Noribeam® Alloy 625
• ASTM F3056standard for SLM Alloy 625
Other alloys available or in development:• Noribeam® 316L • Noribeam® Alloy 718• Noribeam® 17-4PH• Noribeam® 1.4462 – Duplex• Noribeam® Alloy 59• And others ….
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condition RP0,2 /MPa Rm /MPa AS /% KV /J
KSB Noribeam® Alloy
625additive >450 >750 >30 >60
DIN EN 10095 wrought >345 >760 >25 -
ASTM A494 cast >275 >485 >25 -
ASTM F3056 additive >275 >485 >30 -
Noribeam® Alloy 625 microstructure
Noribeam® Alloy 625 samples and test coupons
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Quality AssuranceApproval for SaleKSB sales approval of AM parts requires:
• Material data sheets (MDS)
• Inspection plans
• Legal review
• Insurance secured
Customers are assured of part quality
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Customer benefit:AM consulting and manufacturingWhy KSB as your partner?• Expertise in complete process:
R&D, design, manufacturing and quality assurance
• Represented in international AM standardization groups
• First company certified for AM of pressure boundary parts, by TÜV Süd
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KSB AM consulting
and production
Standardization DIN / CEN / ISO TC 261
ASTM F42
ASME BPVC
API
Accredited test lab
ISO/IEC 17025
Work groups AM VDMA
DGM expert committee AM
Bavaria: Bay. Innovativ, ...
Testing of AM parts in industrial environment BASF, Framatome, …
Consultancy technology screening
design (DfAM)
process reliability
materials R&D development of
materials for AM
international research projects
Manufacturing own machines
– metal
– polymer (FDM)
external partners
Auditing of AM process and parts partner: TÜV Süd
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Thank you for your interest!
Questions?
Christine [email protected]
Website: https://www.ksb.com/en-global/company/innovation/additive-manufacturing
© Copyright KSB SE & Co. KGaA 2021
Technology that makes its mark
Energy ConversionEfficient and Reliable OperationKSB is the global market leader for pumps and valves for energy supply applications. • Fossil-fuelled power stations• Combined cycle power stations• Renewable energy plants• Nuclear power plants Class 1, 2, 3 and non-
classified pumps and valves according to all relevant standards
KSB products installed in over 270 NPPs globally
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The following slides are additional examples of business cases for additive manufacturing.
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AM business case:Shorten development time for pump design optimization
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Challenge: • Nuclear power plant with
challenging requirements for operating range for the charging system pumps, requiring physical verification tests
Solution• Impellers and diffusers required
for hydraulic tests were LPBF printed in days and were tested in full size test system within a week
Benefits• Required results delivered in
weeks, rather than months
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KSB RVMVertical multistage barrel pull-out pump
AM business case:KSB seal coverextended sizes
model classes for different shaftdiameters / seals
• all-over cooling / heating
• external fluid circulation possible
• complete emptying of cooling/heating chamber, noventilation system needed
• operating pressures up to 40 bar
• models for different mechanicalseals
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model classes – seal cover part on substrate plate with almost no supports
high pressure testsassemblyI AM @ KSB I August 2021 I
AM business case:New products in serial production
Leakage detector Eta SYT
Measures leakage of mechanical pump seal
Product designed for additive manufacturing
• Compact design, maximum integration of functions
• Production by AM is lowest cost option
• 100s / year
R&D, first design studies ReDesign for Hybrid AM
finished part and assemblyfinal design in serial production28 I AM @ KSB I August 2021 I
Leckage detectorEta SYT
Pump seal monitoring and diagnostics
Benefits:
• displaying the leakage rate
• information about sealingwear / damage, enablingpreventative maintenanceon pump seal
• easy to install
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AM business case:Obsolete component replacement
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Challenge • Nuclear power plant in Eastern Europe • Plant needed to replace casings on 6 pumps, and did not want to replace the entire
pump• Plant was no longer able to source the needed components
Solution• Additive manufacturing of the molds (binder jet with sand), followed by standard
casting and finishing (Rapid Casting)• KSB established a detailed Quality Control Plan• Customer provided 3D files • KSB created files for printing the molds, including designing offsets for areas
to be machined• KSB used sand binder jetting machine to print the molds followed by casting,
machining and inspection
Benefit• Lower costs• Much faster, weeks rather than months
AM at KSBRapid Casting with Binder JetPrinting of molds and cores with ExOne
• Printing binder onto sand
• Much faster compared toconventional
• Almost no post-processing
• High flexibility for production of prototypes orlow volume series
Located at KSB Standard Alloys, and KSB foundries in Germany31 I AM @ KSB I August 2021 I