Development of Distortion Prediction and Computational Methods for Powder Bed Additive Manufacturing
Driven by...
PROBLEM
An absence exists with suitable distortion prediction tools resulting in ad-hoc rules of thumb to compensate and mitigate the problem.
OBJECTIVE
Benchmark and validate physics-based thermal distortion prediction and mitigation tools for commercialization. Results will lead to a 3X to 4X reduction in development time.
TRL - Currently 4 targeting 6
Lead Organization: GE Research, Supporting Organization(s): United Technologies Research Center (UTRC), Honeywell, Pan Computing, LLC, University of Louisville, Penn State University, CDI Corporation
Start Date: 09/01/2014
End Date: 02/28/2016
APPROACH
• Define canonical features
• Validation of distortion prediction • Distortion compensation
• Curriculum development
??BENEFITS
• Create the ability to virtually evaluate and optimize processes & product alternative for reduced cost (iterations reduced from 5+ to less than 2)
• Rapid deployment of virtual AM process evaluation through wiki and AM transfer functions
IMPLEMENTATION
• GE Leap Engine
• Various other aerospace components
??In-Process Quality Assurance (IPQA) for Laser Powder Bed Production of Aerospace Components
Driven by...
PROBLEM
No commercially available reliable IPQA system. Post process inspection becoming a field unto itself.
OBJECTIVE
Develop an in situ IPQA process that is not material or platform dependent.
Lead Organization: GE Aviation Supporting Organization(s): Areojet
Rocketdyne, Honeywell, Burke E. Porter Machinery Co., B6 Sigma, Techsolve, Montana Tech
Start Date: 10/01/2014
End Date: 03/15/2016
APPROACH
• Establish CTQs
• Determine what sensors are most sensitive to CTQs • Test on Multiple platforms and materials
• Compare with post process analysis
BENEFITS
• Material and platform independent In-Situ IPQA process • Reduced post process inspection time required
IMPLEMENTATION
• Commercialize the IPQA process with the help of Burke E. Porter Machinery Co.
Both programs for GE happen to end in late February and Mid-March of 2016. Perhaps once these programs are completed is when we will hear about SGLB being used for GE mass production of LEAP engines. At the end of the program involving SGLB, it says word for word as implementation, "Commercialize the IPQA process with the help of Burke E. Porter Machinery Co." And we all know SGLB has patents for their technology. Even if GE and others get credit for developing, SGLB will surely get a large piece of the pie.
