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Sirris Workshop - Additive manufacturing in aviation and aerospace 13/05/2014
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www.thalesgroup.com
OPENCe document ne peut être reproduit, modifié, adapté, publié, traduit, d'une quelconque façon, en tout ou partie, ni divulgué à un tiers sans l'accord préalable et écrit de THALES.
Developments on Additive Manufacturing
Yannick CADORET – Thales (TGS)
Corporate Engineering
13th May 2014 – SIRRIS
TRN : 0001-0009968705
2 /2 /
OPENTRN : 0001-0009968705 – 13th May 2014 – SIRRISThales Global Services/ Modèle : 87204467-DOC-GRP-FR-001
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1. The Thales Group in few words
2. General introduction on Additive Manufacturing
3. Additive Manufacturing activities
4. Conclusions
Outlines
3 /3 /
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1. The Thales Group in few words
2. General introduction on Additive Manufacturing
3. Additive Manufacturing activities
4. Conclusions
Outlines
4 /4 /
OPENTRN : 0001-0009968705 – 13th May 2014 – SIRRISThales Global Services/ Modèle : 87204467-DOC-GRP-FR-001
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Whenever critical decisions need to be made, Thales has a role to play.
In all its markets — aerospace, space, ground transportation, defence and security —
Thales solutions help customers to make the right decisions at the right time and act accordingly.
World-class technology, the combined expertise of 65,000 employees and operations
in 56 countries have made Thales a key player in keeping the public safe and secure, guarding vital
infrastructure and protecting the national security interests of countries around the globe.
Profile
Collective intelligence for a safer world
A balanced revenue structure
Defence
55%
Civil
45%
Revenues in 2012
14.2 billion euros
Employees
65,000 (workforce under management at 31 Dec. 2012)
Research and development
2.5 billion euros(approx. 20% of revenues)
Shareholders (at 31 May 2013)
French State
27%
DassaultAviation
26%
Float
47%
of which employees 3%
Global presence
56 countries
5 /5 /
OPENTRN : 0001-0009968705 – 13th May 2014 – SIRRISThales Global Services/ Modèle : 87204467-DOC-GRP-FR-001
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Mission statement
WHEREVER SAFETY AND SECURITY
ARE CRITICAL, THALES DELIVERS.
TOGETHER, WE INNOVATE WITH OUR CUSTOMERS
TO BUILD SMARTER SOLUTIONS. EVERYWHERE.
6 /6 /
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Markets we serve
DEFENCEAEROSPACE SPACE SECURITYGROUND
TRANSPORTATION
Dual marketsMilitary & Civil
TRUSTED PARTNER FOR A SAFER WORLD
7 /7 /
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Worldwide operations
Employees
65,000(workforce under management
at 31 Dec. 2012)
Global presence
56countries
GLOBAL REACH, LOCAL EXPERTISE
8 /8 /
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Global leadership
€14billion
in revenues
N°1worldwide
Payloadsfor telecom satellites
Air Traffic Management Sonars Security for interbank transactions
N°2worldwide
Rail signalling systems In-flight entertainmentand connectivity
Military tacticalradiocommunications
N°3worldwide
Avionics Civil satellites Surface radars
9 /9 /
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Ground based radar (GM400)
Thales Air Systems
Radiocommunications productsThales Communications & Secutity
Portable Infra-red CameraThales Optronics
Large variety of Materials & Processes with complex require ments
Multifuntion Targeting Pod (Damocles)Thales Optronics
Active-Array AntennaThales Airborne Systems
Space amplifiersThales Electon Devices
Human System Interfaces Thales Avionics
Communication SatelliteThales Alenia Space
Wide range of products within the Group
10 /10 /
OPENTRN : 0001-0009968705 – 13th May 2014 – SIRRISThales Global Services/ Modèle : 87204467-DOC-GRP-FR-001
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1. The Thales Group in few words
2. General introduction on Additive Manufacturing
3. Additive Manufacturing activities
4. Conclusions
Outlines
11 /11 /
OPENTRN : 0001-0009968705 – 13th May 2014 – SIRRISThales Global Services/ Modèle : 87204467-DOC-GRP-FR-001
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� Additive manufacturing (AM) is a layer-by-layer technique of producingfunctional end products directly from a digital model
� Good Ability to produce geometrically complex near-net shape designswith substantial reductions in cost and time
� This process also refers to Direct Manufacturing, Rapid Prototyping, 3Dprinting….
3D digital
model
Additive Manufacturing – General Introduction
12 /12 /
OPENTRN : 0001-0009968705 – 13th May 2014 – SIRRISThales Global Services/ Modèle : 87204467-DOC-GRP-FR-001
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Additive Manufacturing
Applications
Aerospace
Medical / Dental
AutomotiveTooling
Additive Manufacturing – General Introduction
13 /13 /
OPENTRN : 0001-0009968705 – 13th May 2014 – SIRRISThales Global Services/ Modèle : 87204467-DOC-GRP-FR-001
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Additive Manufacturing – Global Market (Wolhers Report 2013)
Source : Wolhers Associates, Inc.
� Compound Annual Growth Rate (CAGR) of 28,6% in 2012 (2,204 Bi llions)
Evolution of the professional-grade industrial Additive Manufacturing
systems > 5000$
Total around 57.000 AM systems
14 /14 /
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STRENGHTS
� Elimination of design constraints,
� Allow to produce parts with complex geometry, (no
additionnal costs related to complexity)
� Build speed, reduction of lead time, flexibility,
� No Tooling
� Dimensionnal accuracy,
� Wide range of materials,
(polymers, metals, ceramics…)
� Introduction of new functionnalities,
(honeycomb strcture, cooling channels…)
� Maintenance and repair of high value parts,
� Green manufacturing, clean, minimal waste.
WEAKNESSES
� Surface roughness,
� Density, porosity,
� Lack of data,
� Dimensionnal limitations,
� Low volume manufacturing,
Additive Manufacturing – General Introduction
Supply Chain ?
15 /15 /
OPENTRN : 0001-0009968705 – 13th May 2014 – SIRRISThales Global Services/ Modèle : 87204467-DOC-GRP-FR-001
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Stereolithography (SLA) Fused Deposition Modeling (FDM) Powder Bed
Blown Powder
Additive Manufacturing Processes
Additive Manufacturing
Liquid based process Solid based process Powder based process
PolymersCeramics
MetalsPolymers
PolymersMetals
Ceramics
The selection of a process is depending on costs, number of parts, leadtimes, performances, complexity of design…
16 /16 /
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NASA Technology Readiness Levels (TRLs)
Beyond MCRL & TRL 5/6 a robust procurement strategy & fullqualification of the production process are mandatories for mediumand low series (>100 parts/year)
Aerospace
17 /17 /
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1. The Thales Group in few words
2. General introduction on Additive Manufacturing
3. Additive Manufacturing activities
4. Conclusions
Outlines
18 /18 /
OPENTRN : 0001-0009968705 – 13th May 2014 – SIRRISThales Global Services/ Modèle : 87204467-DOC-GRP-FR-001
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Scope
� Additive Manufacturing processes : Stereolithography, powder bed, blown powder…
� Materials : Resins, Polymers, Metals (Ti, Al, Steels, Ni-based), Ceramics
� Supply Chain, Quality Assurance & Standards
Participants
� More than 10 Legal Entities coming from all technical areas (Aerospace, Space, Defence, Security, Ground Transportation),
� A focal point is clearly identified to ensure a good communication and reporting within this group.
Objectives
� Identify the major benefits and the Enginnering drivers for the Additive Manufacturing Technology,
� Coordinate the initiatives at Group level (transverse projects),
� Promote transverse exchanges within Thales (share experiences),
� Develop a network of Engineers & Specialists within the Group,
� Avoid the duplication of work,
One Team – One Thales
Group work is required to promote the growth of AM within Thales
19 /19 /
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Thales Expectations - Manufacturing
� Manufacture of complex parts that can not be machined, casted or forged,
� Reduction time to market (in comparison with casting and forging),
� Reduction of lead time, increase in build speed,
� Topological Optimization,
� Reduce Weight (Honeycomb structures),
� Reduce Costs,
� Reduce Buy to Fly Ratio Buy to Fly Ratio : Cost associated with the amount of raw materials required to produce a finished part),
� Introduction of new functionalities (cooling channels),
� Decrease the number of assembled components,
Additive Manufacturing is expected to make Thales products moreattractive and more competitive
20 /20 /
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Metallic Materials � Copper� Aluminum (AS7G0.6)� Aluminum (2618, 6061, 7075…)� Titanium (TA6V)� Steels & Stainless Steel (316L)� Ni-based alloys & CoCr� Low CTE alloys (Fe based, Al based) ?
Polymers Materials � Thermoplastics PEEK� Acrylate� Epoxies� PP, Polyamide (PA), ABS� Elastomers
Ceramic Materials� Alumina� Cermet� Structural Ceramic (Si 3N4) ?
Thales Expectations - Materials
21 /21 /
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FP7 – EU AMAZE
Additive Manufacturing Aiming Towards Zero Waste & Efficient Production of High-Tech Metal Products
22 /22 /
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Work program topics addressed� FP7-FoF NMP 2012-4� High-perfomance manufacturing technologies in terms of efficiency, robustness and accuracy
Title � AMAZE� Additive Manufacturing Aiming Towards Zero Waste and Efficient Production of High-Tech Metal
Products
Duration� 54 months (4,5 years)� Starting date : January 2013
Total Budget� Around 20M€
Coordinator� European Space Agency� 28 partners from 10 countries� 19 from industry, 8 from academia and 1 intergovernmental agency� www.amaze-project.eu
FP7 AMAZE Project
23 /23 /
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AMAZE Participants – 28 Partners from 10 countries
24 /24 /
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PhD on mechanical properties (Corporate Engineering)
PhD Student
� Victor CHASTAND – Engineer from Centrale Lille
Title of the PhD
� Studying the mechanical behaviour and the damaging mechanisms of metallic parts produced by Additive Manufacturing
Duration
� 3 years (October 2013 to October 2016)
Location
� Meudon-la-Forêt (Thales Global Services)
Supervisors
� Ecole Centrale Lille : Eric CHARKALUK & Philippe QU AEGEBEUR
� Thales Global Services :Yannick CADORET
Partner laboratory
� Laboratoire de Mécanique de Lille (LML)
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First Results : Effect of the manufacturing direction
The anisotropy in the tensile properties is negligible
E (GPa) Rm(MPa)Rp0,2 (MPa)
Differences Titanium 1,4% 8,1% 2,0%
Aluminium 0,4% 2,2% 2,1%
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Effect of the manufacturing direction
The anisotropy in the tensile properties is negligible
E (GPa) Rm(MPa)Rp0,2 (MPa)
Differences Titanium 1,4% 8,1% 2,0%
Aluminium 0,4% 2,2% 2,1%
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OPENTRN : 0001-0009968705 – 13th May 2014 – SIRRISThales Global Services/ Modèle : 87204467-DOC-GRP-FR-001
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Effect of the manufacturing direction
The anisotropy in the tensile properties is negligible
E (GPa) Rm(MPa)Rp0,2 (MPa)
Differences Titanium 1,4% 8,1% 2,0%
Aluminium 0,4% 2,2% 2,1%
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OPENTRN : 0001-0009968705 – 13th May 2014 – SIRRISThales Global Services/ Modèle : 87204467-DOC-GRP-FR-001
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But… the elongation at break is anisotropic
Possibilities
� Fusion of the different layers
� Surface qualities
� Porosities
Analysis
� Microscopic observations completed
Possible consequences
� Fatigue could be anisotropic
The anisotropy in the elongation at break will be studied (observations)
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OPENTRN : 0001-0009968705 – 13th May 2014 – SIRRISThales Global Services/ Modèle : 87204467-DOC-GRP-FR-001
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� Standardization is necessary to disseminate innovation & facilitate the access to the market
� Active Contributions from complementary sectors are needed :
� End Users (Thales, Safran, Airbus…),
� Technical Centers (IREPA, CETIM-CERTEC…),
� Powder Manufacturers (ARKEMA, SULZER…),
� Equipment Manufacturers (PHENIX Systems, EOS, Renishaw…)
� Suppliers of manufactured parts (MB Proto, Esteve…).
� Thales Global Services participates to Standardizati on Organizations
� UNM 920 (French Committee)
� ISO TC 261 (International Committee)
Standardization activities on Additive Manufacturing
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OPENTRN : 0001-0009968705 – 13th May 2014 – SIRRISThales Global Services/ Modèle : 87204467-DOC-GRP-FR-001
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� UNM 920 (France) created in July 2010
� Scope : processes by adding material – manufacturing of workpieces directly from a 3D model without using tools
� Domains : all, especially mechanical industries, aeronautics and odontology
� Several standards published so far
� Contact : Catherine LUBINEAU
� Thales Global Services is participating to this Com mittee
Standardization activities on Additive Manufacturing
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OPENTRN : 0001-0009968705 – 13th May 2014 – SIRRISThales Global Services/ Modèle : 87204467-DOC-GRP-FR-001
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� ISO TC 261 (Technical Committee) created in 2011
� Standardization in the field of Additive Manufacturing (AM) concerning their processes, terms and definitions, process chains (Hard- and Software), test procedures, quality parameters, supply agreements and all kind of fundamental
� 4 Working Groups
� Working Group 1 : Terminology (Coordination : Sweden )
� Working Group 2 : Methods, processes and materials (Coordination : Germany )
� Working Group 3 : Test methods (Coordination : France )
� Working Group 4 : Data processing (Coordination : UK)
� Global coordination from DIN (Deutsches Institut für Normung)
� 14 participating countries including FRANCE (AFNOR)
Standardization activities on Additive Manufacturing
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OPENTRN : 0001-0009968705 – 13th May 2014 – SIRRISThales Global Services/ Modèle : 87204467-DOC-GRP-FR-001
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Integrations of both mechanical and electronic functions o n 3D designs� From Additive Manufacturing (AM) to Molded Interconnect Devices (MID)
Source : CICOR (3D-MID Technology)
When Mechanic meets Electronic…
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OPENTRN : 0001-0009968705 – 13th May 2014 – SIRRISThales Global Services/ Modèle : 87204467-DOC-GRP-FR-001
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1. The Thales Group in few words
2. General introduction on Additive Manufacturing
3. Additive Manufacturing activities
4. Conclusions
Outlines
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OPENTRN : 0001-0009968705 – 13th May 2014 – SIRRISThales Global Services/ Modèle : 87204467-DOC-GRP-FR-001
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� Additive Manufacturing is offering innovation that our customers are
looking for (reduce weight, reduce costs, add new functionalities),
� It is now possible to manufacture components made from polymers,
metals and even ceramics with good physical and mechanical
properties,
� Additive Manufacturing should enable Thales to provide more
competitive products with higher performance in a challenging
environment,
� 3D printing technology is still in the early stages for industrial
application (aeronautic, space, defense),
� Supply chain in Europe is emerging for metallic functional parts,
� A robust & coherent supply chain has to be consolidated before to
consider serial production (e. g. > 100 part/year),
Conclusion – Take away
Additive Manufacturing is considered in Thales as a key technology forthe near future
www.thalesgroup.com
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