1

www.cranfield.ac.uk

WAAMMat Programme Overview

Professor Stewart Williams

January 2017

2

• Cost savings compared to current manufacturing processes •  Lead time reduction compared to forgings • Performance enhancement through

Ø Replacement of e.g. castings by higher performance materials Ø Weight savings by topological optimisation Ø New materials Ø Mixed material systems

WAAM business drivers

3

WAAM business driver – cost saving case studies - Bombardier rib

Design option Mass (kg)

BTF Cost (£k)

Cost red.

Original machined 20 12 16.2 - WAAM + machining 20 2.3 5 69%

Design option Mass (kg) BTF Cost (£k) Cost red.

Original, machined 36 12 1.6 -

WAAM + machining 36 2.3 0.7 55%

4

WAAM systems - where we are aiming - HELP!

Aluminium: •  14 months for

forging •  4 months for

machining •  90% waste

Titanium: •  10 times worse

problems

5

Worlds largest 3D printed (metal) part – 6 m long 300 kg aerospace grade aluminium spar

6

WAAM system developments – multi robot systems for parallel processing

7

WAAM – major technical challenges and activities

• System development - CAD drawing to part • Software and full automation

•  WAAMDesign •  WAAMSoft •  WAMMCtrl •  WAAMAPIs

• Hardware •  Process monitoring •  Fault detection •  Component cooling

• New materials and combinations •  High strength aluminium alloys •  Superalloys •  Refractory metals •  Maraging steels

•  In process NDT •  Qualification – Q3

8

CAMSo'ware•  Toolpathplanning•  Intelligentpar//oning

•  Buildstrategyalloca/on

•  Interfacemanagement

•  Layerheightcontrol

•  BuildsequenceGUI

•  Autobuildstrategy

•  Control

Performance•  Tensile•  Fa/gue•  Fracturetoughness

•  Crackpropaga/on

•  Corrosion•  Effectofdefects

WAAMMat – Technical Programme Overview

Processes•  WAAMvariants•  Processalgorithms•  Buildstrategies•  Higherbuildrates•  Increasedfidelity•  Wallwidthcontrol•  Compensa/onstrategies

•  WLAMandWLAAMOtherprocesses•  2.5Drolling•  Alternatecoldworkmethods

•  Grainstructuremeasurement

•  Hybridmanufacture•  IntegratedNDT•  Defectrepair

New•  Highstrength

aluminium•  Refractory

metals•  Maragingsteels•  Superalloys•  Metalfoams•  MMCs•  LowCTE

materials•  Mixedmaterial

systems

Hardware•  SoRplasma•  Precisionwirefeeding

•  Localshielding•  Ruggedisa/on•  Processmonitoring

•  Controlsystems•  Robo/csystems•  Machinetools•  Largestructures•  Mul/processes

Commercialsystems

WAAMMatTechnicalProgramme

SystemDevelopment DesignToolsMaterials

MatureWAAM WAAMIndustrialApplicaCons

Qualifiedmaterials

OpCmisaCon•  CADtoCAM•  Hybridmanufacturetool

•  Knowledgeexpertsystem

•  Computeraidedplanning

Designcapability

9

CAMSo'ware•  Toolpathplanning•  Intelligentpar//oning

•  Buildstrategyalloca/on

•  Interfacemanagement

•  Layerheightcontrol

•  BuildsequenceGUI

•  Autobuildstrategy

•  Control

Performance•  Tensile•  Fa/gue•  Fracturetoughness

•  Crackpropaga/on

•  Corrosion•  Effectofdefects

WAAMMat – Technical Programme Overview

Processes•  WAAMvariants•  Processalgorithms•  Buildstrategies•  Higherbuildrates•  Increasedfidelity•  Wallwidthcontrol•  Compensa/onstrategies

•  WLAMandWLAAMOtherprocesses•  2.5Drolling•  Alternatecoldworkmethods

•  Grainstructuremeasurement

•  Hybridmanufacture•  IntegratedNDT•  Defectrepair

New•  Highstrength

aluminium•  Refractory

metals•  Maragingsteels•  Superalloys•  Metalfoams•  MMCs•  LowCTE

materials•  Mixedmaterial

systems

Hardware•  SoRplasma•  Precisionwirefeeding

•  Localshielding•  Ruggedisa/on•  Processmonitoring

•  Controlsystems•  Robo/csystems•  Machinetools•  Largestructures•  Mul/processes

Commercialsystems

WAAMMatTechnicalProgramme

SystemDevelopment DesignToolsMaterials

MatureWAAM WAAMIndustrialApplicaCons

Qualifiedmaterials

OpCmisaCon•  CADtoCAM•  Hybridmanufacturetool

•  Knowledgeexpertsystem

•  Computeraidedplanning

Designcapability

FullysupportedPar/allysupportedNotyetsupported

10

WAAMMat Research Programme Structure

Stewart Williams Programme Director

Filomeno Martina Programme Manager

Jialuo Ding Lead Researcher

PhD Researchers (YB, SR, JH, KA, EE, XX, GM, FM)

Research fellows and associates (RF - GP, AM, TK, MM) (RA – PK, ZP, AC)

Academic Support (HL, PC, SG, RT, TC, WS)

Technicians (FN, NX, JP)

11

WAAMMat Programme – Cranfield team

WAAMMatProgrammePartnerOverview

StewartWilliamsProgrammedirectorJialuoDingAutoma/on,soRware,partbuildingFilomenoMarCnaProgrammeManagerPaulColegroveColdwork,modelling,HelenLockettDesignanddesigntoolsSupriyoGangulyMetallurgyandF&DTRalphTatum,TomCarrolOp/calinstrumenta/onWojciechSuderWLAMandWLAAMJamesWidbourneControlsystemsYifanZhaoSignalProcessing

AcademicCranfield

11xPhDstudentsØ  KwasiAyarkwa–novelAlstructuresØ  GianroccoMarinelli–refractorymetalsØ  JanHönnige–alterna/vecoldworkØ  XiangfangXu–mixedmaterialsØ  FlorentMichel–SoRwareforWAAMØ  EloiseEimer–AldevelopmentØ  PhilippeBridgeman-manufacturing

strategiesØ  Alex–ProcessmonitoringandcontrolØ  PhillipeTaiye–Fa/guebehaviourü  2xnewPhDstudentsstarCngJan

2017•  VariousMScprojects

Students

GonzaloPardalCooling,localshielding,hybridlaserAnthonyMcAndrewMul/dimensionrolling,partbuilding,modellingPawelKurzsnikyControlsystemsandsoRwareZsoltPinterAldeposi/on,partandcomponentbuildingArmandoCaballeroNewmaterialsThomasKissingerOn-linesensingMichelangeloMortelloWLAMandWLAAMUzamiPartbuilding

Currently29peopleonprogramme+3technicians

ResearchersCranfield

12

WAAMMat Programme - Academic Partners

InsCtuCon LeadinvesCgator Technicalarea Resource

ManchesterU PhilPrangnell, MaterialsScienceandModelling–Q3 1xres,1xPhD

UofNo]ngham SteveSharples On-linegrainsizemeasurement 1xres

IITBombay Karunakaran Integratedmachining,peening 2xPhD

HeriotWa_U AndrewMoore Flowvisualisa/on,processmonitoring 2xPhD

NEUniversityChina YuchunZhai Aluminiumwiredevelopment

OpenUniversity SanjooramPaddea Residualstresscharacterisa/on 1XRes

BathUniversity StephenNewman Processmonitoring 1xRes

CoventryUniversity XiangZhang Fa/gueandDT,effectsofdefects–Q3 1xRes,2xPhD

StrathclydeUniversity GarethPierce In-processNDT–Q3 1xRes

BristolUniversity HarryCoules Fa/gueandDT,effectsofdefects–Q3 1xPhD

SurreyUniversity Aluminiumwirequality–Q3 1xPhD

Del'University IanRichardson Thermalcyclesimula/ons,microstructure–Q3 1xPhD

IST LuisaQuin/no NDTanddesign 2xPhD

11 Academics + 18 researchers/students > 60 people in total working on WAAM

13

•  WAAMMat is a rolling technology programme incorporating a wide range of projects and activities •  Industry sponsored research • Projects funded by outside

bodies (e.g. EU, EPSRC, TSB) • PhDs • Masters projects •  Internally funded projects

•  Currently 70 projects – total value >£4.5M,

WAAMMat Programme – features

IndustryEUUKNa/onalOther

14

WAAMMat Programme – Industry partner types

PartnerType Rights Requirements

Full •  PerpetualroyaltyfreelicensetoallforegroundIPfromthecoreprogrammewhilstpartners

•  Fullaccesstodetailofallresearchoutputsincoreprojects

•  AccesstobackgroundIPneededtoexploitWAAM•  Memberofindustryadvisorygroup

•  Sponsorshipofresearchprojectswithminimumrequirementof£120kinatwoyearperiod

•  SponsoredresearchmustformpartoftheWAAMMatcoreprogramme

Associate •  Visibilityofallresearchoutputsfromthecoreprojects

•  AccesstobackgroundIPneededtoexploitWAAM•  Memberofindustryadvisorygroupbyinvita/ononly

•  Contribu/ontotheWAAMMatbyforexample

•  Non-coreresearchprojectsponsorship

•  Smallerresearchprojectcontribu/on

15

WAAMMat industry members

WAAMMatFull AssociateorcollaboraCve

UK Interna/onal UK Interna/onal

BAESystems LockheedMar/n CCFE VolvoTrucks

Globalrobots NEIMM Delcam Constellium

DSTL UTRC AirbusGroup Fanuc

GlenAlmond FMC PWP AirProducts

LindeGases AWE EWM

OfoFuchs Technicalarc Fronius

Thales SelectArc

Weir Bekaert

NormanFoster&P

Indiscussion

3Dsystems Roxel Boeing NorthropGruman

Keppel AirLiquid

16

Basic WAAM Hardware

WAAM Basic System and IP

NC Controller

Motion System

Power Source

Material Supply

Additional Processes (e.g. Rolling, PDHT)

Additional Functionality

Finishing (Milling/Grinding)

Inspection (Shape/Defects

Feature identification

Geometric Data Input (3D CAD)

Process Parameters

Conversion to Layer Geometry (Slicing)

Machine Tool/ Robot Path Generation

Software and Process Data

Intellectual Property

Material properties

WAAM - IP

Design Handbook

Process Algorithms

Compensation strategies

Feature build strategies

Additional processes

Deposition geometries Build sequence

17

WAAM Software

WAAM process procedure

CADmodelmodifica/onto

preforms

Pathplanningandpost-processingtorobot/CNCprogramme

Processmonitoringandcontrol

18

WAAM Commercialisation – WAAM Systems and Services (WSS)

WSS

SystemIntegratorsSystemsupply

HardwareManufacturersHardwaresupply

WAAMSystems

WAAMServices

JobshopsBatch

manufacture

So'wareWAAMSoRWAAMCtrlWAAMDesignWAAMCost

HardwareWAAMShieldWAAMSenseWAAMCoolWAAMWork

PrototypingPrototypeparts

ConsultancyPartevalua/on•  WAAM

manufacture•  CostbenefitSystemdesign

19

Potential WAAM systems under discussion

Type System FuncConality ApproximateSaleValue LikelysectorA Verylowcost

CNC•  Cheapanaloguepowersource•  LowcostCNC•  Limitedso'warefuncConality•  Limitedbuildvolume

£10k-£30k 3DprinCng,enthusiasts,educaCon

B Lowcost-highendrobot+digitalpowersource

•  Al/Steels/Inconel/Etc.-GMAW•  Simpleparts,shapesandfeatures•  Mediumso'warefuncConality

(maybebespoke)

£60k–£300kHardwaretypical:£120kSo'waredependingonfuncConalitycancostupto£100k

Generalengineering,oil&gas,defence,

C1 Highcost-highendroboCcssystem(1ormorerobots)

•  PlasmabasedincludingTi•  1ormorerobots•  MulCpleprocesses-Integratedcold

work+machining+metrology+NDT•  Highso'warefuncConality

£200k–£600kFor2robots:£250kandincludesmachiningheadsandtoolchangers

Aerospace,highvaluemanufacturing,energy,defence,repair

C2 MediumcostCNCbasedsystem

•  Limitedbuildvolume(1m3)•  LimitedfuncConality•  PlasmabasedincludingTi•  Highso'warefuncConality

£250k–£750k

Aerospace,highvaluemanufacturing

D Highcost-highendCNC(roboCc+CNC)

•  Integratedcoldwork+machining•  NDT+metrology•  Allmaterialsincl.Ctanium•  Highso'warefuncConality

£0.5–£2million Aerospace