Additive Manufacturing in ITP

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1 Additive Manufacturing in ITP María Sierra Materials & Processes Dept. Jornada de fabricación aditiva de componentes metálicos IK4-LORTEK 27 Noviembre

2 INDEX COMPANY PRESENTATION ADDITIVE MANUFACTURING TECHNOLOGY ALREADY AVAILABLE IN ITP CURRENT TECHNOLOGY DEVELOPMENT FOR NEXT COMPONENTS FUTURE WORK 2

3 WHAT WE DO? 3

4 ITP S GLOBAL PRESENCE 4

5 ITP IN FIGURES ITP Group Main Figures (in thousand euros) Sales EBITDA Post-tax results Material and nonmaterial investments R&D Investment Capital and reserves EBITDA against sales 16,16% 20,34% 18,25% % R&D Investment/sales 9,40% 9,54% 12,02% Sales/employee Cost of labour/sales 24,80% 26,53% 27,71% Participations SENER AERONÁUTICA 53,125 % ROLLS-ROYCE 46,875 % Staff ITP PCB ITR ITA ITA Mexico ITP Engines UK Aeromaritime Total

6 ITP S UNIQUE EXPERTISE 6

7 CIVIL LARGE COMMERCIAL LPT Trent XWB Additional Information Airframe: Airbus A350 XWB -800, -900 & Thrust: 74,000 lb 92,000 lb Fan Diameter: 118 in 7

8 ADDITIVE MANUFACTURING - OVERVIEW FROM THIS TO THIS 8

9 ADDITIVE MANUFACTURING - OVERVIEW NEAR 100% MATERIAL UTILISATION REDUCED MATERIAL COSTS. IMPACT THE MANUFACTURE OF FUTURE AERO ENGINE COMPONENTS (CURRENT BUY TO FLY RATIOS RESULT IN MASSIVE AMOUNTS OF WASTE) SIMPLE/MINIMAL TOOLING REDUCED TOOLING COSTS REDUCED TIME TO MARKET NEAR NET-SHAPE CAPABILITY REDUCED REMOVAL OPERATIONS DESIGN FREEDOM INCREASED ENHANCED PRODUCT CAPABILITIES REPAIR CAPABILITY INCREASED LOWER TOTAL LIFE CYCLE COST 9

ADDITIVE MANUFACTURING - OVERVIEW Capabilities Arc+ Wire (SMD)

(LMD) Laser+ powder bed Selective Laser Melting (SLM) Cost/kg Medium

efficiency High High Low High Fusion capability High Medium Medium

cracking in difficult to weld materials Low Low Low Medium Deposit

10 ADDITIVE MANUFACTURING - OVERVIEW Capabilities Arc+ Wire (SMD) Laser/EB+ Wire (EBWD) Laser+blown powder Laser Metal Deposition (LMD) Laser+ powder bed Selective Laser Melting (SLM) Cost/kg Medium Medium Medium High Build rate High High High Low Filler usage efficiency High High Low High Fusion capability High Medium Medium Medium Near net shape Low High High Very high Capability of avoiding cracking in difficult to weld materials Low Low Low Medium Deposit density Medium High High Very high Suitablity for complex parts Low Medium Medium High 10

11 DEVELOPMENT BENCH TEST H/W PRODUCTION ADDITIVE MANUFACTURING IN ITP - OVERVIEW PRESENT NEAR FUTURE FUTURE Small-Medium Size Complex Non-Critical Components SLM Repairing Components made from Difficult to Weld Alloys (e.g. MAR-M-247) LMD Features and Repairs at Stressed Areas Non-Critical Components made from Weldable Alloys (e.g. Inconel 718 and Ti) LMD Non-Structural Features SMD LPT Blades SLM LPT NGVs Instrumented or Not SLM Static Cast Components Instrumented or Not Low Temperature Aerodynamic Rigs SLM SLM Instrumentation Rakes and Probes SLM 11

12 ADDITIVE MANUFACTURING IN ITP - OVERVIEW SMD, LMD AND EBWD VS FORGING Cost savings of approximately 35-40% SMD, LMD AND EBWD VS CASTING Cost savings of approximately 10% or less Cost savings of approximately 10% or less 12

13 TECHNOLOGY ALREADY AVAILABLE IN ITP INCO 718 SMD IN PRODUCTION FOR THB HANDLING LUGS 13

TECHNOLOGY ALREADY AVAILABLE IN ITP CONVENTIONAL MANUFACTURING DESIGN ADAPTED TO MANUFACTURING SELECTIVE LASER MELTING

Need to allow adequate access to attach the tubes in position and to provide access to the brazing filler CONSIDERABLE

DESIGN Aerodynamic profiles, thickness and profiles distribution as required, curved cavities 1 mm diameter INTEGRATED

14 TECHNOLOGY ALREADY AVAILABLE IN ITP CONVENTIONAL MANUFACTURING DESIGN ADAPTED TO MANUFACTURING SELECTIVE LASER MELTING MANUFACTURING ADAPTED TO DESIGN DESIGN LIMITED BY MANUFACTURING (radius, minimum thicknesses, profiles). Need to allow adequate access to attach the tubes in position and to provide access to the brazing filler CONSIDERABLE REWORKS or even scrap parts due to brazing process LONG MANUFACTURING TIMES (Machining, welding, brazing) FREEDOM OF DESIGN Aerodynamic profiles, thickness and profiles distribution as required, curved cavities 1 mm diameter INTEGRATED TUBES No risk of reworks and scraps because of tubes brazing ONLY ONE ITEM Manufacturing time reduced, less risk of reworks/scraps 14

15 TECHNOLOGY ALREADY AVAILABLE IN ITP COMPARISON OF TIME DELIVERY VS COST (REAL CASE FOR A SPECIFIC RAKE) ADVANTAGE DISADVANTAGE 15

16 TECHNOLOGY ALREADY AVAILABLE IN ITP COMPLEX DESIGNS ACHIEVABLE COMPLEX COOLING PASSAGES REINFORCING LATTICES INTEGRATED PRESURE TUBES LESS INTRUSIVE COMPACT DESIGNS 16

17 CURRENT TECHNOLOGY DEVELOPMENT - SLM AIRFOILS MADE FROM POLIMERIC MATERIALS FOR COLD RIGS 17

18 CURRENT TECHNOLOGY DEVELOPMENT - SLM CAST COMPONENTS ONLY FOR FIRST BENCH TESTS FIRST TRIAL SECOND TRIAL 18

19 CURRENT TECHNOLOGY DEVELOPMENT - SLM VANES INSTRUMENTED OR NOT ONLY FOR FIRST BENCH TESTS 19

20 CURRENT TECHNOLOGY DEVELOPMENT - SLM MAIN ADVANTAGE OF A REDUCED TIME DELIVERY MINIMIZE DELAY IN THE ENGINE TEST PROGRAM MILESTONE YEAR 1 YEAR 2 YEAR 3 YEAR 4 PERFORMANCE VIBRATIONS ENDURANCE CYCLIC THERMAL INGESTIONS CONTAINMENT FLIGHT TEST BED 1/1 1/2 2/1 2/2 2/3 3/1 3/2 3/3 4/1 4/2 4/3 5/1 6/1 6/2 7/1 8/1 20

21 CURRENT TECHNOLOGY DEVELOPMENT - LMD LMD INCO 718 TBH FEATURES LMD MM247LC SEAL FINS REPAIR GENERAL CASTINGS REPAIR LMD Ti 6AI 4V THIN SHEET REPAIR 21

22 Additive Manufacturing- Mechanical Properties PROOF STRESS UTS ANISOTROPY FATIGUE CREEP CLOSE TO FORGING: SLM PROCESS SAME AS FORGING WITH LOW SCATTER BETWEEN CAST AND FORGING CAN BE DECREASED CHANGING DEPOSITION PARAMETERS DEPENDANT ON POROSITY, LACK OF FUSIONS AND SURFACE FINISH. IN SLM LESS THAN FORGING DUE TO FINE MICROSTRUCTURE 1 1 Inco 718 Forging SLM Plane XY SLM eje Z Inco 718 Forging SLM Plane XY SLM eje Z 0 0 YIELD(MPa) UTS(MPa) Inco 718 SLM Mechanical properties at 600ºC 22 PROPRIETARY INFORMATION STRICTLY CONFIDENTIAL

23 Additive Manufacturing- Mechanical Properties 23

Additive Manufacturing- Mechanical Properties Internal

defects Need of determination of scatter band in

24 Additive Manufacturing- Mechanical Properties Internal Surface Integrity Microporosity Lack of Fusion Defects Reduced HCF from forging material. Need of improving process capability to further reduce defects Need of determination of scatter band in fatigue properties Need of NDT development: Laser ultrasonic testing in MERLIN 24

25 CURRENT TECHNOLOGY DEVELOPMENT FOR NEXT COMPONENTS SMD, LMD, EBWD BUILD RATES SLM BUILD RATE Current build rate to ensure full density in commercial machines TARGETS IN MERLIN TO INCREASE THE DEPOSITION RATE MEETING QUALITY REQUIREMENTS 25

SUPPLIERS WITH SUITABLE QUALITY SUITABLE IN-PROCESS NDT TECHNIQUES POST

26 FUTURE WORK NEED TO DEVELOP COMPETITIVE BUILD RATES AND CAPACITIES TECHNIQUES TO BUILD DIFFICULT TO WELD HIGH TEMPERATURE SUPERALLOYS POWDER SUPPLIERS WITH SUITABLE QUALITY SUITABLE IN-PROCESS NDT TECHNIQUES POST PROCESSING METHODS TO ACHIEVE ACCEPTABLE INNER SURFACE FINISH AND SURFACE INTEGRITY 26

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