Additive Manufacturing at GE

Additive Manufacturing at GE
Greg Morris
Imagination at work.
Who We WereWho We Are
Pre-GE Acquisition
MTI & RQM
Founded 1994
Introduced DMLM to NA in 2003
135 employees
Services included:
Engineering & Design
Additive (Metals/Polymers) (25 additive machines)
Post-Processes (Machining, Thermal Processing, Finishing)
Collaborations/JVsi.e. MicroTek Finishing w/BinC, etc.
Customer Base: Aerospace, Medical, Consumer Goods, Energy
Page 3
7/27/2014
GE Acquisition of MTI & RQM (Nov 2012)
Additive
Development
Center
- GEA focus
- Other GE
- Select Externals
Additive
Lean Lab /
Pilot Production
- Low rate initial production
Page 4
7/27/2014
Manufacturing Technology Development
DMLM (Today)
Material Development
Machine Development
Process Development
------------------------Test Fixture/ Tooling Mfg
Prototype Manufacturing
Material Development Test Article Manufacturing
Pre-Production Mfg
Physics Models
Early Process Dev
GRC
TRL / MRL 0
ID New
Technologies
Additive
Development
Center (ADC)
TRL / MRL 3
Develop
Technical
Technologies
Feasibility
Early Production Mfg

Product VSE
Production Process Dev
Low Rate Manufacturing
Final Production Site (Auburn, AL)

High Rate Manufacturing
Entitlement Cost
Production
Additive
Lean Lab
(ALL)
TRL / MRL 6
Mature
Technologies
TRL / MRL 9
Support
Production
Page 5
7/27/2014
How the Process Works...
Basic Process (DMLM)

AM Process
Thermal
Processing
Post Processing
and Inspection
3D CAD Model
Final Part
Prep for Process
GE Proprietary Information
Additive Modalities
Types of Additive
Photo Courtesy: Arcam

Photo Courtesy: Stratasys
Photo Courtesy: EOS
Photo Courtesy: 3D Systems
Rapid Prototyping? Additive Manufacturing? 3D Printing?

Export Authorization, ECCN: 9E991, NLR
Polymers - SLA
Photos Courtesy: 3D Systems
Polymers - SLS
Photos Courtesy: EOS
Photos Courtesy: Materialise
Polymers - FDM
Photos Courtesy: Stratasys
Polymers - PolyJet
Metals
Photo Courtesy: EOS
Photo Courtesy: ORNL
Photos Courtesy: Within Labs
Nano Additive Mfg.
Photos Courtesy:
Other 3D Printing
Photo Courtesy:
Additive at GE Aviation...
GE Aviation Additive:
FDM: (1) Fortus 900
SLA: (2) 500s, (2) Vipers

(3) ProJet 3500
Phenix: (1)
ARCAM: (8) A2(xx)
PolyJet: (1) Connex 500
C-L: (1) M2
EOS: (11) M270s

(4) M280s
SLM: (2) 250HL

Photos Courtesy: 3D Systems, Stratasys, EOS, SLM
GE Aviation Additive Support:
CAD Modifications
Multi axis milling
Multi axis Turning
Extrude Hone
Airflow test stand

CMM/Laser Scan
5-axis EDM Hole Drill

Wire EDM
Production Prep:
Inspection
DMLM: (7) M270s
Powder Size Analysis

Thermal Processing: (1)

Vacuum Stress, (1) HIP
Design Matters...
Design to the Process Critical
Instrument Probe - 2005
Instrument Probe - 2007
Successful builds (no crashes)

Less cost to produce
Higher test life
More accurate probes
Lower number of probes
required
Better data collection
Shorter fabrication time
CopyrightGE2014
General Information
Electric Company, U.S.A.
Proprietary
Design For Additive
Topology & Shape Optimization
Crowdsourcing Design Challenge

Public challenge
to find new
design strategies
for additive
manufacturing
150 entries in less
than 30 days
Top designs will
be manufactured
and tested by GE
Makers Guild
Original design
Corporate initiative to gain exposure and

expertise in the world of 3D printing
Learn about:
Build orientation
Shape capability
Support structure
Example entry
Design Challenge and the Potential of

Additive
Tapped into 750k+ online community
Over 700 entries received
Many submissions over 80% weight
reduction
Traditional Design
Parts Grown and Tested
Winning Design
7/27/2014
Materials are the Reason Why
Material Properties Drive Applications
Super Alloys (2005)

Many similar to wrought strengths
Some materials characterized
Large opportunity for novel alloy
development
SS
316L
Inco
625
Inco
718
MS-1
Ti64
W
Cu
AlSi10
Mg
6061
T6
Hast
X
CoCr
17-4
PH
Ti 6242
SS
15-5
TiAl

YS (ksi)
"UTS (ksi)"
200
180
160
DMLM
Wrought
ASTM
140
120
Vertical
100
ASTM
80
60
40
DMLS - V DMLS - H Wrought Wrought
Low
High
Horizontal
Solution
Heat Treatment
Elongation (%)
"Hardness (HRC)"
42
38
34
30
Melt Pool Directionality Similar to Wrought

Vertical Grain Growth Isotropic / Homogeneous
Typical Equiaxed
Grain Structure
ASTM
ASTM
26
22
18
DMLS - V DMLS - H Wrought Wrought

Low
High

180
YS (ksi)
"UTS (ksi)
160
DMLS
EBM
Wrought
ASTM
140
Vertical
ASTM 120
Horizontal
100
Elongation (%)
35
30
25
20
Typical Alpha + Beta

Widmanstatten Structure
Similar to DMLS
Alpha on Deposition Layer
Finer than
DMLS or EBM
ASTM
ASTM
15
10
5
0
"Hardness (HRC)
After the Buildthe Role of Post Processes
Machining
Surface
Finishing
Metallurgical
Lab
Thermal
Processing
Special
Processes
Additive Metal Challenges
Build Learnings
Witness Line due to a power outage
EBM Cake Limit of Internals
7/27/2014
How GE Aviation is Using Additive

Metals
Leveraging AM NPI Hardware
7th set of HPTs in 6 years

Substantial cost and lead time reduction
Design refinement options
Fuel Swirlers
Land-based Gas Turbine Engines

90 parts in (3) months
Met testing timetable
Eventually will be castings
DMLM Design Advantage
LEAP Fuel Nozzle
DMLM Fuel Nozzle Design History

Begin TAPS
Development
2000
2001
CoCr DMLM Material

Development
2002
2003
2004
2005
2006
2007
LEAP 1 piece
DMLM Nozzle
2008
2009
2010
GEnx certifies
Traditional Mfg.
GE Proprietary Information22 piece construc.
DMLM for
prototype testing
DMLM supply
chain acquisition
2011
2012
2013
LEAP FETT
LEAP 56 Next Generation Fuel Nozzles

19 Fuel Nozzles in each engine
40K full production
20 pieces to 1
5x durability improvement
25% weight reduction
(compared to GEnx)
Fuel Nozzle is a very efficient
heat exchanger
Exploring Optimized Structures

Optimized Result: 30% less weight
Original
Re-designed (conceptual)
Combine parts to eliminate weight

Performance gains
Maintenance reduction
Optimal structure designs
EXPERIENCE ON EBM - TiAl

Advantages of the EBM process:
low level of internal defects, no typical casting
defects, therefore low scatter in material properties

homogeneous microstructure
very fine grain size, leading to good material properties, in particular fatigue
properties, and no need for grain refinement
no limitations in chemical composition
no residual stresses due to high process temperature
little waste material: powder can be recycled as the oxygen pick-up is very
low
45
AM Integration Within GE Corporation
Additional Considerations
Accelerating Adoption
Process
Automation
Predictive
Analysis Tool
Diversified
Materials
Surface Finish
Validation
Tools
Process
Variation
Present
Process
Monitoring
Application
Specific Machines
Accepted
Best Practice
Gradiated
Materials
Higher Capacity
Machines
Accepted Industry
Standards
2014
2016
2018+
Growing Acceptance with Continuous Innovation

Gaps and Challenges

General
Rapid Qualification
& Materials Database
IP: Rights & Tracking
NDT / Internal Flaw detection
Supply Chain:
Development & Protection
Available Materials
Technician Skill Level
Process Specific
Surface Finish
Distortion
Build Volume
Throughput
Process Monitoring and
Control
Supply Chain Shift?

From
To
More Local?
Field Operation
Substantial supply chain

challenge in remote locations
Spare / Repair parts on-site?
Mobile Additive Center concept
Parts Inventory
Local ability to grow parts?

Controls inventory
Balance inventory with
needs/delivery
Flexibility for design changes (no
order minimum)
Broad Trends
Challenging IP landscape
Further consolidation (all areas)
Increased adoption of technologies
Accelerating innovation
New business models
160
140
120
100
Applications
80
IP
60
Alloys
40
20
0
2012
2013
2014
2015
2016
What Phase Are We In?
Creators &
Pioneers
Early
Adopters
Primary
Majority
Secondary
Majority
Technology Maturation and Acceptance Curves
Holdouts
Additives Potential::
Global Mfg. Output:

~$10.5 Trillion
~$2.2 Billion Professional

Industrial Additive Market
~0.02% of total global Mfg.
output
What if was 1%?...=$100B!
Thank You!
Imagination at work.

Additive Manufacturing at GE

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Additive Manufacturing at GE

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Additive Manufacturing at GE

Who We WereWho We Are

Introduced DMLM to NA in 2003

Engineering & Design

Additive (Metals/Polymers) (25 additive machines)

Post-Processes (Machining, Thermal Processing, Finishing)

Collaborations/JVsi.e. MicroTek Finishing w/BinC, etc.

Customer Base: Aerospace, Medical, Consumer Goods, Energy

GE Acquisition of MTI & RQM (Nov 2012)

Manufacturing Technology Development

Early Production Mfg

Final Production Site (Auburn, AL)

How the Process Works...

Basic Process (DMLM)

Prep for Process

Photo Courtesy: Arcam

Photo Courtesy: Stratasys

Photo Courtesy: 3D Systems

Photo Courtesy: Stratasys

Rapid Prototyping? Additive Manufacturing? 3D Printing?

Photos Courtesy: 3D Systems

Photos Courtesy: EOS

Photos Courtesy: Materialise

Photos Courtesy: Stratasys

Photo Courtesy: Stratasys

Photo Courtesy: EOS

Photo Courtesy: ORNL

Photos Courtesy: Within Labs

Nano Additive Mfg.

FDM: (1) Fortus 900

SLA: (2) 500s, (2) Vipers

ARCAM: (8) A2(xx)

PolyJet: (1) Connex 500

EOS: (11) M270s

SLM: (2) 250HL

Photos Courtesy: 3D Systems, Stratasys, EOS, SLM

GE Aviation Additive Support:

Airflow test stand

5-axis EDM Hole Drill

DMLM: (7) M270s

Powder Size Analysis

Thermal Processing: (1)

Design to the Process Critical

Instrument Probe - 2005

Instrument Probe - 2007

Successful builds (no crashes)

Design For Additive

Topology & Shape Optimization

Crowdsourcing Design Challenge

Corporate initiative to gain exposure and

Design Challenge and the Potential of

Parts Grown and Tested

Materials are the Reason Why

Material Properties Drive Applications

Super Alloys (2005)

Material Properties Drive Applications

Melt Pool Directionality Similar to Wrought

DMLS - V DMLS - H Wrought Wrought

Material Properties Drive Applications

Typical Alpha + Beta