3D printing

1. 1
GKN Aerospace Additive Manufacturing
Rob Sharman – Head of Metallics Technology
Societe Generale 2014

2. 2
Additive Manufacturing Terminology
The ASTM definition:
“The process of joining materials to make objects from 3D model
data, usually layer upon layer, as opposed to subtractive
manufacturing methodologies, such as traditional machining”
EBM
EBFFF
3D-Printing
SLS
SLMDMD
DMLS
FDM ALM
SLA
LENS
LDW
WAALM
Polyjet
LC

3. 3
High geometric complexity enables next
generation small prismatic components.Accurate but near-net
parts and claddings
High material fusion rate and deposition technique enable
large scale near-net shape parts or grow-outs
Deposition of powder
fused using laser in a
chamber to produce
part
LASER
(POWDER)
Free deposition of
wire fused using
plasma arc to
produce part
PLASMA
(WIRE)
Deposition of wire fused using electron
or laser beam in a chamber to produce
part
EB
(WIRE)
LASER
(WIRE)
Laser or electron beam selectively
fuses powder on a bed in a
chamber to produce part
LASER
(POWDER)
EB
(POWDER)
PICTURE
DESCRIPTION
APPLICATIONS
DEPOSITION POWDER BED
DESIGNATED
ICON
Powder / binder
system requiring
down-stream
consolidation
BINDER
(POWDER)
Net-shape parts
achievable at
automotive rates
Additive Manufacturing
Fraunhoffer ILT
Arcam
TWI
Cranfield
University
GKN Aerospace
Höganäs Digital Metal®
TWI
GKN
AerospaceGKN Aerospace
Cranfield University
Cranfield
University
SMALL PUDDLE
DEPOSITION
• Lower material throughput
deposition systems
• Focus on Ti and Ni alloys
• Nearer net-shape add-ons and
prismatic pre-forms
• Engine component fabrication,
component repair and grow-outs (cost
& performance)
• Broad range of medium-size engine
and structures components;
fabrications
LASER
P/BED
• Lowest
material thru-
put
• Ti, Ni and steel
alloys
• Nearest-net
• Intricate hi-
value
components
• Engine parts
and small
inserts
EB
P/BED
• Low material
thru-put
• Ti6Al4V
• Highly net-
shape
• Small –
medium
prismatics
• Structural
brackets,
engine parts
and fabrications
INDIRECT
P/BED
• Low material
thru-put
• Cast-able
alloys
• Highly net-
shape
• Complex
castings and
inserts
•Engine parts
and
fabrications
LARGE PUDDLE
DEPOSITION
• High material throughput
deposition systems
• Focus on Ti
• Large-scale pre-forms
• Initial cost-driven introduction
• Applications including large aero
structure components
EBP LL L EB B
Virginia Tech
GKN
Aerospace
Fraunhoffer ILT
Sciaky
Reis
Robotics

4. 4
History & Lifecycle of Technology Adoption
Composites
1930 19501940 19701960 1980
NC Machine
Invented
Robotic
process
reaches
manufacturing
maturity
Applied
across
multiple
industries
Fiberglass
Patented
Carbon Fiber
production
begins
All fiberglass
aircraft;
H-301
Dragonfly
CNC Machining (Subtractive)
Over 40 Years!
Over 40 Years!
20001990 2010
787
commercial
aircraft first
flight
Metallic AM
Entire history of AM!
Gartner Hype Cycle

5. 5
Ti Growth in Airframe Applications
Growth in use of Ti in Aerostructures
Of particular note in recent years has been the rapid growth of Ti and its alloys in airframe
applications
This has been predominately linked to the growth in CFRP due to the better compatibility of
Ti alloys (galvanic corrosion and thermal expansion) with CFRP

6. 6
AM within Processing Portfolio
AM ONLY
Delivery Drivers Cost Drivers Performance Drivers
AM IN COMPETITION WITH OTHER TECH
L EB
Powder BedDeposition
LEBP L
DEPOSITION
POWDER BED
DEPOSITION
Norsk Titanium
EADS GKN
Data Release
DfM
Complete
Tooling
Ready
1st Article
Production
< 95
WEEKS
< 12
WEEKSAM
Conventional

7. 7
AM Adoption
Cost Reduction - Aero
Niche/High Performance - Aero & Auto
Near net pre-forms Added features Improved functionality/performance
1
Introduction of both new materials and processes is challenging
Conservatism and healthy cautiousness are barriers to initiatives
Step-wise approach is implicitly required
“INITIAL” phase
Generally cost-driven implementation
Allows both GKN and customer (and supply chain) to acquaint
themselves with challenges and opportunities
“NEXT” phase
Builds on “INITIAL” phase
Allows all parties to fully exploit AM technology benefits
PRIMARYSECONDARY
DERIVATIVE SIMILAR NEW

8. 8
Generic Conventional Component

9. 9
Generic Conventional Component
 Mat’l = 4.85kg
 Swarf = 4.08kg
 Mat’l = 1.08kg
 Swarf = 0.31kg
 Part = 0.77kg
Machining Route to Man’fAM Route to Man’f

10. 10
Generic Conventional Component
 ~5 x less feed stock
 ~13 x less swarf
 Conventional design (not yet
optimised for weight)

11. 11
The possibilities and benefits are exciting
Unlocks Materials Science
Only uses the material you need - uses less material
Design no longer constrained by conventional manufacturing processes
Allows design for functionality
Speed and flexibility of development
A revolutionary set of technologies – not evolutionary
Phased introduction is implicitly required
Secondary derivative structure before primary optimised
Need to pin variables to gain acceptance
Process and material are now linked like never before
Big challenge to the industry in evaluation
How to certify
New and novel QA techniques required
AM Current R&D ProgrammesGKN Additive Manufacturing

12. 12
GKN Investment and Growth in Additive Manufacturing
GKN sees additive manufacturing as a high priority technology
GKN is investing and expanding our portfolio in AM across the business,
leveraging our expertise across divisions
GKN is expanding and establishing new Centres of Excellence in additive
manufacturing, building on existing capability to build a global network:
Powder bed - Filton (UK)
High rate Deposition - St Louis (USA)
Fine Deposition - Trollhatten (Sweden)
Materials - New Jersey (USA)
Operating across the whole value chain, from raw material, design, process
and application
Partnered with key academic institutions, customers and suppliers
Understand the criticality and potential of design, and GKN is developing the
skills and design toolbox to take advantage of the disruptive nature of additive
manufacturing