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Sirris Workshop - Additive manufacturing in aviation and aerospace 13/05/2014

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Page 1: Sirris_am in aviation and aerospace_thales case studies

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

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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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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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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

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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.

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Markets we serve

DEFENCEAEROSPACE SPACE SECURITYGROUND

TRANSPORTATION

Dual marketsMilitary & Civil

TRUSTED PARTNER FOR A SAFER WORLD

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Worldwide operations

Employees

65,000(workforce under management

at 31 Dec. 2012)

Global presence

56countries

GLOBAL REACH, LOCAL EXPERTISE

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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

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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

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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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� 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

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Additive Manufacturing

Applications

Aerospace

Medical / Dental

AutomotiveTooling

Additive Manufacturing – General Introduction

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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

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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 ?

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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…

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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

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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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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

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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

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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

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FP7 – EU AMAZE

Additive Manufacturing Aiming Towards Zero Waste & Efficient Production of High-Tech Metal Products

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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

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AMAZE Participants – 28 Partners from 10 countries

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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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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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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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� 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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� 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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� 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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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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1. The Thales Group in few words

2. General introduction on Additive Manufacturing

3. Additive Manufacturing activities

4. Conclusions

Outlines

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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

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