Motivations, Opportunities and Challenges of Additive Manufacturing for Space Application Franck Mouriaux General Manager Structures RUAG Schweiz AG RUAG Space Dearborn, Mai 6 th 2015
Why AM? design complexity for free function integration manf flexibility for free FREEDOM design MASS reduction lead TIME reduction 2 RUAG Space 10.05.2015
How AM? design PROCESS PRODUCT analysis MATERIAL postprocessing SUPPLIER verification qualification 3 RUAG Space 10.05.2015
Where AM? EVERY WHERE 4 RUAG Space 10.05.2015
5 RUAG Space 10.05.2015 SENTINEL-1
SENTINEL-1 Antenna Support Bracket 1 Original Design 1.6kg 88.7Hz 163MPa 2 First Optimisation Loop 1.2kg 88.7Hz 6 RUAG Space 10.05.2015
SENTINEL-1 Antenna Support Bracket Original loading Original electrical grounding Original design enveloppe Original interfaces 7 RUAG Space 10.05.2015
SENTINEL-1 Antenna Support Bracket Original loading Original electrical grounding Original design enveloppe Original interfaces 8 RUAG Space 10.05.2015
SENTINEL-1 Antenna Support Bracket 3 Final Design 0.936kg 91.5Hz 103MPa 9 RUAG Space 10.05.2015
Model Preparation Optimis. Interpret. Design Detailed Optimis. Detailed Verif. Additive Manf Baseline CAD Design space Load Cases Topology Optimization Topology Loadpath Optimisation loops CAD interpretation 10 RUAG Space 10.05.2015
Model Preparation Optimis. Interpret. Design Detailed Optimis. Stress Verif. Additive Manf Understand where to start Definition of design space Definition of load cases Definition of material 11 RUAG Space 10.05.2015
Model Preparation Optimis. Interpret. Design Detailed Optimis. Stress Verif. Additive Manf Optimization problem formulation: Objective: Minimize Mass OR Compliance Constrains: Vol. frac. / Stress / Freq / Manf Variables: Element densities 12 RUAG Space 10.05.2015
Model Preparation Optimis. Interpret. 4 5 6 7 Obtained topology must be realized into a proper CAD design Understand results from optimization Observe similarities Identify primary and secondary load paths? Cross sections geometries depending on structural behaviour Understand and apply design principles from AM Printing orientation Overhang angle consideration Heat dissipation and stress concentration Post-processing consideration 13 RUAG Space 10.05.2015
Model Preparation Optimis. Interpret. Design 5 6 7 Loadpath from topology iterations interpretated as CAD model with Solidthinking Evolve. 14 RUAG Space 10.05.2015
Model Preparation Optimis. Interpret. Design Detailed Optimis. 6 7 Many sections highlighted proved to be redundant after incorporating mounting interfaces. Findings from Loop2 topology iterations implemented in the new CAD Cross member could be discarded Shear web could be replaced with cross members 15 RUAG Space 10.05.2015
Model Preparation Optimis. Interpret. Design Detailed Optimis. Detailed Verif. 7 Static Strength Verification Dynamic Verification 16 RUAG Space 10.05.2015
Model Preparation Optimis. Interpret. Design Detailed Optimis. Detailed Verif. Additive Manf The parts printed from an EOS M400 from the company CITIM. Material: AlSi10Mg (AA357-AA359 casting alloy) 17 RUAG Space 10.05.2015
Model Philosophy Qualification Flight Geometrical verification Modal verification Quasi-static load test Geometrical verification Modal verification Quasi-static load test Sine vibration tests (3-dir.) Random vibration tests (3-dir.) Vibration Test 18 RUAG Space 10.05.2015
Verification Comparison of QM geometry with CAD model and identification of deviation. Computer tomography scan with resolution of 320 m 19 RUAG Space 10.05.2015
Verification Test specimens were printed within the same print job as the two S1 AM brackets. 20 RUAG Space 10.05.2015
Verification In-plane (XZ) low level sine sweep to verify the frequency requirement. Frequency search spectrum Frequency [Hz] Amplitude [g] Speed [oct/min] direction 5 to 2000 0.2 2 One sweep up TEST RESULTS Predicted Measured 1st Eigen frequency (X) 90.0 Hz 91.4 Hz Z 2nd Eigen frequency (Z) 106.9 Hz 109.0 Hz -X X-response Z-response 21 RUAG Space 10.05.2015
Verification Out-of-plane (Y) low level sine sweep to verify the frequency requirement. TEST RESULTS Predicted Measured 1st Eigen frequency 106.9 Hz 107.8 Hz Y 22 RUAG Space 10.05.2015
Qualification Strength verification under static, sine and random loading. SG09: 246 SG08: 282 23 RUAG Space 10.05.2015
Qualification 24 RUAG Space 10.05.2015
Topology Optimisation CAD Interpretation Manufacturing Verification Testing Additive Manufacturing Development Process Design / Optimisation Manufacturing Verification / Testing Functional analysis Topology optimisation CAD Interpretation Size/Shape Optimisation Detail Stressing Optimisation Post-Processing Samples Definition Process Control Quality Control Test Definition Qualification Testing Model Correlation 25 RUAG Space 10.05.2015
Main Challenges Acceptance of the technology by customers and authorities Qualification and control of the materials and processes Development of new engineering thinking Development of new design tools Development of additive manufacturing technologies RUAG 26 Space 10.05.2015
AM in Space more than a hype! Lockheed Martin Testing 3-D-Printed Subsystems On A2100 Space Bus "My goal is to have over 50% of the structures 3-Dprinted within two to three years," Richard Ambrose, executive vice president of Denver-based Lockheed Martin Space Systems Jul 24, 2014 Lockheed Martin Testing 3-D-Printed Subsystems On A2100 Space Bus AWIN ONLY content from Aviation Week 27 RUAG Space 10.05.2015
Advanced Spacecraft Structures 3D-printed LVA Ring Large dimensions parts 3D-printed isogrid central tube with integrated interfaces 28 RUAG Space 10.05.2015 Full integration of metal to composite
Advanced Spacecraft Structures Integrated metal coated plastic 3D-printed waveguides Integrated high power 3Dprinted heatpipes Surface printed electrical circuits Thermo-optical surface coating 29 RUAG Space 10.05.2015
Advanced Spacecraft Structures Thin plies CFRP sandwich with ultralight 3D-printed core with anti-telegrahing feature Lightweight 3D-printed brackets with adaptive stiffness and damping High efficiency 3D-printed solar cells 30 RUAG Space 10.05.2015
Advanced Spacecraft Structures 31 RUAG Space 10.05.2015
Thank you for your attention! Franck Mouriaux General Manager Structures RUAG Schweiz AG RUAG Space Schaffhauserstrasse 580 8052 Zürich Switzerland Tel. +41 44 306 21 37 Fax. +41 44 306 27 50 Mobile: +41 78 709 56 71 franck.mouriaux@ruag.com http://www.ruag.com 32 RUAG Space 10.05.2015