Additive Manufacturing in Metals -Applications Review-

Transcription

1 Additive Manufacturing in Metals -Applications Review- Dr. Héctor R. Siller Escuela de Ingeniería y Ciencias Tecnológico de Monterrey

2 Agenda Introduction Metals Additive Manufacturing at a Glance Performance Challenges Industrial Case Studies Additive Manufacturing of turbine blades Freeform Fixturing for gas and aerospace turbine applications Process chain for the manufacturing of biomedical implants Powertrain components prototyping Tec National Lab in Additive Manufacturing Ongoing Research Topics Héctor Rafael Siller Carrillo Tecnológico de Monterrey 2

3 Metal Additive Manufacturing at a Glance (Erick Ramirez, PhD student and co-owner of 3D Factory)

4 Aeronautic Applications Héctor Rafael Siller Carrillo Tecnológico de Monterrey 4

5 Additive Manufacturing of Turbine Blades Performance Challenges in Aeronautic Applications Rolls Royce UTC at the University of Nottingham Héctor Rafael Siller Carrillo Tecnológico de Monterrey 5

6 Additive Manufacturing of Turbine Blades Performance challenges in Aeronautic Applications Melting temp. ~ 1455 C unalloyed Young Modulus~ 240 Gpa (Steel 210 Gpa) Density 8.9 g/cc (steel 7.8 g/cc) Tensile Strength Mpa Héctor Rafael Siller Carrillo Tecnológico de Monterrey 6

7 Additive Manufacturing of Turbine Blades Wide spectrum of Aeronautic Components Tight tolerances. Freeform surfaces. Extreme working conditions (1,500 C) Internal cooling blades (1,000 C) Courtesy of Honeywell Aerospace Chihuahua Héctor Rafael Siller Carrillo Tecnológico de Monterrey 7

8 Additive Manufacturing of Turbine Blades Design for Additive Manufacturing Héctor Rafael Siller Carrillo Tecnológico de Monterrey 8 Courtesy of Honeywell Aerospace Chihuahua

9 Additive Manufacturing of Turbine Blades Running projects Honeywell- Tecnológico de Monterrey Life Cycle Assessment Materials characterization Corrosion studies Residual Stresses Postprocessing Coatings Hot Isostatic Pressing Héctor Rafael Siller Carrillo Tecnológico de Monterrey 9

10 Freeform Fixturing with Additive Manufacturing Innovative Concepts for Fixturing of Turbine Blades for Gas and Aerospace Industries Based on the elastic deformation of a diaphragm wall (similar to collets) with the shape of the component. The thickness of the diaphragm wall can be manipulated as to create rigid locators. Gameros, A., Axinte, D, Siller, H. R., Lowth, S., & Winton, P. (2016). Experimental and numerical study of a fixturing system for complex geometry and low stiffness components. ASME Journal of Manufacturing Science and Engineering (In Press). Héctor Rafael Siller Carrillo Tecnológico de Monterrey 10

11 Freeform Fixturing with Additive Manufacturing Validation of a Full Box Prototype Experimental Validation Displacement with Coordinate Measuring Machine (CMM) Contact interactions with Finite Element Analysis Héctor Rafael Siller Carrillo Tecnológico de Monterrey 11

12 Freeform Fixturing with Additive Manufacturing Performance Validation Héctor Rafael Siller Carrillo Tecnológico de Monterrey 12

13 Biomedical Applications Héctor Rafael Siller Carrillo Tecnológico de Monterrey 13

14 Biomedical Devices and Additive Manufacturing Process chain for the fabrication of cranial implants Clinical requirements of customized implants Courtesy of 3D Factory Héctor Rafael Siller Carrillo Tecnológico de Monterrey 14

15 Biomedical Devices and Additive Manufacturing Process chain for the fabrication of cranial implants (Erick Ramirez, PhD student and co-owner of 3D Factory) Héctor Rafael Siller Carrillo Tecnológico de Monterrey 15

16 Biomedical Devices and Additive Manufacturing Process chain for the fabrication of cranial implants (Erick Ramirez, PhD student and co-owner of 3D Factory)

17 Biomedical Devices and Additive Manufacturing Re-design of exoskeleton components Courtesy of Wearobot Design attempts Héctor Rafael Siller Carrillo Tecnológico de Monterrey 17

18 Biomedical Devices and Additive Manufacturing Proof of Concept of intervertebral spacers Design iterations Design validation with Finite Element Analysis Héctor Rafael Siller Carrillo Tecnológico de Monterrey 18

19 Automotive Applications Héctor Rafael Siller Carrillo Tecnológico de Monterrey 19

20 Automotive Applications and Additive Manufacturing Powertrain Components Prototyping Courtesy of SISAMEX / Renishaw Héctor Rafael Siller Carrillo Tecnológico de Monterrey 20

21 Research at Tecnológico de Monterrey Research Networking Ongoing Topics: 1.- Freeform Fixturing Systems 2.- Reverse Engineering for AM 3.- Metrology 4.- Materials Characterization 5.- Process Calibration Interests: 1.- Process Monitoring 2.- Adaptive Control 3.- Materials Design 4.- Post Processing 5.- Design Customization Additive Manufacturing in Metals Industry Partners International Collaboration National Collaboration Héctor Rafael Siller Carrillo Tecnológico de Monterrey 21

22 Research at Tecnológico de Monterrey Monterrey Additive Manufacturing New Capabilities MSc. In Manufacturing Systems Doctoral Program in Enginering Sciences Héctor Rafael Siller Carrillo Tecnológico de Monterrey 22

23 Research at Tecnológico de Monterrey Laboratories and Facilities Héctor Rafael Siller Carrillo Tecnológico de Monterrey 23

24 Research at Tecnológico de Monterrey National Lab in Additive Manufacturing Monterrey Héctor Rafael Siller Carrillo Tecnológico de Monterrey 24

25 Research at Tecnológico de Monterrey Extended Capabilities: UNAM Laboratorio Nacional de Manufactura Aditiva, Digitalización 3D y Tomografía Computarizada Héctor Rafael Siller Carrillo Tecnológico de Monterrey 25

26 Talent Human Capital brings Tech Solutions! Industrial Networking Research Facilities

27 Q&A Héctor R. Siller Héctor Rafael Siller Carrillo Tecnológico de Monterrey 27