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LENS Technology Overview

LENS Technology Overview. Complete Solution Offerings. Metal Fabrication & Repair LENS MR-7 LENS 850R Electronic Fabrication & Repair M3D 300P M3D 300CE M3D Solar Lab Full Professional Services Installation & Training System Support Application Support. Additive Manufacturing.

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LENS Technology Overview

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  1. LENS Technology Overview

  2. Complete Solution Offerings • Metal Fabrication & Repair • LENS MR-7 • LENS 850R • Electronic Fabrication & Repair • M3D 300P • M3D 300CE • M3D Solar Lab • Full Professional Services • Installation & Training • System Support • Application Support

  3. Additive Manufacturing • From ASTM: • “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” Desired Shape Actual Shape from Additive Manufacturing Machine

  4. Metal Additive Manufacturing • Invented ~20 years ago • Building or repairing parts layer-by-layer using engineering metals • Stainless steel • Aluminum • Cobalt-Chrome • Titanium • Superalloys • Usually high performance requirements • Quality is very important • Rapidly gaining industrial acceptance

  5. Two Common Ways of Making Layers • Powder Bed • Part is grown in a bed of powder – powder is laid out first, then the powder is selectively sintered or melted • The end result isn’t visible – it is buried in a powder “cake” • After processing, the excess powder is removed and the part is revealed • Example – Selective Laser Sintering/Melting • General features: Can build relatively complex shapes; mechanical properties OK; smaller build volume; cannot repair parts • Freeform • The material is built up on a part in free space – powder and laser are delivered simultaneously • The entire process is visible – powder falls away as you build • Examples – LENS Process • General features: Mechanical properties good; can build less complex shapes; build volumes larger; good for repair

  6. Metal Process Comparison

  7. LENS Process Overview • This section gives an overview of the LENS process • The videos are available on egnyte

  8. LENS Process • Multi Nozzle Powder Delivery • Metal Powder melted by Laser • Layer by layer part repair • 5-Axis range of motion • Closed Loop Controls • Controlled Atmosphere (<10ppm O2) The LENS Process - Repair Toolpath Repaired Part • Near Net Shape • Fully Functional! • Tool path generation • Various methods

  9. The LENS Process

  10. The LENS Process – RPM Shaft Repair Final ground surface Final deposit surface CMM Inspection

  11. LENS Additive Manufacturing Benefits • Can add features or material to a pre-existing structure • Excellent microstructure and material property control • Multi-material capabilities • Ability to process alloys which could not be otherwise made • Complex Geometries • Minimal effect on substrate microstructure

  12. LENS Material and Properties Overview

  13. Quality • Eliminate Defects for Critical Applications • Complete Atmosphere Control • Hermetically-sealed enclosure, complete argon blanket • No interstitial pick-up, no porosity introduced • Laser Power Control • Rapid switching, precise power control • Toolpath Control • Proprietary software, all areas filled • Melt Pool Control • Closed-loop control • Key Process Variable Monitoring • System performance verified 125 micron Best practice – no pores above 5 microns

  14. LENS Materials

  15. LENS Mechanical Properties LENS Mechanical Properties Equivalent to Wrought for many applications Ultimate Tensile Strength Yield Strength

  16. EADS data US Air Force data LENS Ti-6-4 Fatigue Properties Background data from Donachie, M. J. Jr., ed., Titanium: A Technical Guide, ASM International, 1988. US Air Force data edited from: “Mechanical Properties of Laser-Deposited Ti-6Al-4V”P.A. Kobryn and S.L. Semiatin. Proceedings of the 12 Solid Freeform Fabrication Symposium, Aug. 2001. Unpublished EADS Fatigue data, provided by EADS Corporate Research, Munich, with permission 11/24/05, superimposed over published WPAFB data Fatigue strength matches wrought annealed material in independent testing

  17. LENS IN718 Fatigue Properties • HIP at 2150F, 15ksi, 2 hours • Heat-treat 8hr at 1325F, then cooled at 100F/hr to 1150F, then held 8 hrs and air-cooled • LCF testing at 1100F, with an R-ratio of 0.05 Best IN718 Properties of Any Additive Process – In Production at ANAD

  18. LENS System Overview

  19. MR-7 System Overview • Standard LENS MR-7 Features • 300mm x 300mm x 300mm process work area • 500W IPG Fiber Laser • Class 1 laser enclosure, hermetically sealed • 3 axis motion control X,Y,Z • Gas purification system maintains O2 < 10ppm • Dual powder feeders with gradient capability • 380 mm diameter ante chamber • CE Certification available

  20. 850R System Overview • Standard LENS 850R Features • 900mm x 1500mm x 900mm process work area • Class 1 laser enclosure, hermetically sealed • 5 axis motion control X,Y,Z with tilt & rotate table • Gas purification system maintains O2 < 10ppm • 2 powder feeders • 380 mm ante chamber • 1kW IPG Fiber Laser

  21. Toolpath Generation • From CAD Model • Full 3D build-up • Manual Teach-n-Learn • Simple repairs • From scan data • Scan worn area, form point-cloud to make toolpath • Tube-clad, ArcPath… • Utilities to make toolpaths for standard geometries • Other methods available as pilot release options • 5-axis • LaserPath 2-D adaptive The Right Toolpath for the Right Repair

  22. Thermal Imager – Therma-Viz by Stratonics Temperature • Dual wavelength pyrometer • Measure temperature of melt-pool • Calculate cooling rates • Visual thermal profile • Now available on all new LENS Systems Data from H. Sun, OSU

  23. LaserPath Option • 2-D adaptive system to generate and adjust toolpaths • Automatically adapts pre-defined toolpath to fit the exact component to be repaired • In pilot release, first units installed Q4 2011

  24. 5-axis Path Planning Option • 5-axis toolpath generation software • Developed by Open Mind GmbH for LENS 850R • Generate toolpaths for part builds and repairs • In pilot release, first deliveryQ4 2011

  25. LENS Application Overview

  26. Degradation of Machinery Loss of Usefulness Obsolescence 15% Surface Degradation 70% Failure 15% Mechanical Wear 50% Corrosion 20% Fatigue 8% Adhesion 6% Other 7.5% Abrasion 28.5% 3 bodies 23.5% Two body 5% http://www.maintenanceworld.com/Articles/reliabilityplant/Machines-Wear-Out.htm

  27. LENS Application – Critical Component Repair • Industry Need: • Repair high value components that have worn out of tolerance • Value Proposition: • Reduce repair timesup to50%* • Reduced repair costs up to 30%* • Total costs of repair regarding to new part price: • 13% Ti 6-4 (300 EUR new part / 40 EUR LENS repair) • 42% Inconel 718 (200 EUR new part / 80 EUR LENS repair) *compared to wire surface welding process • Solution: • LENS 850R system from Optomec • Spherical Metal Powder

  28. LENS Application – Repair • Industry Need: • Repair of worn impeller in heavy-duty pump • Value Proposition: • Repair of Hard-Iron / Cast Iron (ASTM A532 Class III type A 25% Cr) • Improve on-time deliveries • Solution: • LENS system from Optomec • SS metal powders (improved performance) • Appropriate final machining Heavy duty pump with impeller

  29. LENS Application – Rework • Industry Need: • Reduce scrap from casting processes • Reduce scrap from mis-machining • Value Proposition: • Reduce scrap rate from 10% to ~0% • Improve on-time deliveries • Solution: • LENS system from Optomec • Various metal powders

  30. LENS Application – Rework • Superalloy components • Small repairs • Savings vary on value of part • One facility reports >$1M saved per year

  31. LENS Application – Critical Component Repair Repair Facts: • Material: Ti-6-4 • Engine: T55 – Chinook Helicopter • LENS Advantage: Quality, access to internal features • Two repairs Qualified by U.S. Army • Saving >$10K vs. replace per part http://en.wikipedia.org/wiki/File:Lycoming_T55-GA-712.jpg

  32. LENS Application – Large Component Repair Thermal Spray Replacement Repair Facts: • Materials: Various steels • Application: Power plant repairs • LENS Advantages: Low heat input with full metallurgical bond. • Avoid part replacement, avoid down-time

  33. After Machining After Deposition After Finishing LENS Application – Turbine Component Repair Courtesy: Anniston Army Depot • Repair Facts: • Material: IN718 • Engine: AGT1500 • LENS Process Advantages: Properties, Low Heat Input, Near Net Shape • In Production at Anniston Army Depot, $5M saved in first year

  34. ANAD LENS Process Vane Segment Repairs Repair Facts: • Material: 410SS • Engine: AGT1500 • LENS Process Advantage: Low Heat Input • Both In Production at Anniston Army Depot

  35. LENS Application Examples Thermal Spray Replacement • Repair Facts: • Materials: Various steels • Application: Power plant repairs • LENS Process Advantages: Low heat input with full metallurgical bond • All In Production at RPM and Associates

  36. R&D Applications TiC-reinforced Ti Biomedical Wear resistance TCP-reinforced Ti Biomedical Bone ingrowth TNZT deposition Biomedical Better modulus Low density Ti Biomedical Better modulus HA on Ti Biomedical Biocompatibility Nitinol Biomedical Shape Alumina coating Biomedical Wear Alumina deposition Prototyping Fundamental R&D Co Superalloys IGT Repair GTD-111 IGT Repair Nanotube + Ni Aerospace Fundamental R&D FE Modeling Aerospace Fundamental R&D Single-crystal Aerospace Repair Novel Ti alloys Aerospace Strength Niobium silicide Aerospace Temperature Die cast repair Tooling Repair Carbide cermets Tooling Wear Solidification behavior Various Fundamental R&D Metallic Glasses Various Rapid solidification Hundreds of published technical papers, hundreds of research areas

  37. Deposit optimized wear-resistant coatings Seek to create metal-on-metal wear surfaces for non-congruent implants with articulating bearing surfaces Join biocompatible materials which are difficult to join otherwise Put a solid wear surface on top of a porous bone in-growth material Add antimicrobial agents to deposits LENS Research Applications: Wear Surfaces CoCrMo LENS deposit on wrought CoCrMo 60% TiC 20% TiC 40% TiC Uniformly distributed TiC precipitates throughout a Ti matrix

  38. Research Applications: Fundamental R&D • Understand process/microstructure/property relations • Measure cooling rate with precision • Measure subsequent thermal cycles/tempering • Measure chemistry and correlate with microstructure • Measure properties on macro/micro/nano scale • Simulate and model the process

  39. Ti-6-4 Ti-22-23 Research Applications: Rapid Alloy Screening Ti-6-4 Ti-22-23 • Material Discovery • Analyze chemical grade in one sample • Optimize properties on different locations • Yield strength & modulus of all chemistries between Ti-6-4 and Ti-22-23 measured in one sample • Correlation between chemistry, microstructure and properties in one sample

  40. Research Applications: Rapid Solidification • Cooling Rates of 1000 – 5000oC/s or more are possible • Rapid solidification enables fabrication of sub-micron microstructural features • Nano-scale precipitates are possible • Macro, Micro and Nano structural features can be altered • Create sub-micron features in macro-scale parts

  41. Research Applications: Composites/Ceramics Carbon Nanotube Reinforced Nickel Composites Bulk alumina, fully-dense Ti-35Nb-7Zr-5Ta with 2% boron reinforcement TriCalcium Phosphate + Ti for bioactivity

  42. Industrial Applications: Rapid Manufacturing • Reduces Time to First Part • Reduces Material Costs > 90% • Typical parts have low material efficiency • Suspension mounting bracket 92% material loss • Drive shaft spider 97% material loss Parts in Ti-6-4 and IN718 Courtesy: Red Bull Racing LENS Process benefits: reduced time, cost and waste

  43. Industrial Applications: Feature Addition Hybrid Manufacturing gives Time Compression & 30% Cost Reduction • Tough to cast, long lead time: 52 weeks to cast • Hybrid route: machined disk with details added by LENS process • Delivery Time: 3 Weeks. • Superior Design: reduced weight • Design changes implemented during development Electronics Housing in 316SSCourtesy: Sandia National Laboratories Size: 30cm diameter

  44. Medical Applications

  45. LENS Application – Custom-made product • Industry Need: • Custom-made bone fixation plate for pelvis • Locally improved functionality principle and product shape suitability • Value Proposition: • Improved volume/weight ratio (40%) • Improved product bending and torsion properties • Improve on-time deliveries • Solution: • LENS 850R system from Optomec • Ti-6-4 Powder • Functional-gradient principle (firm homogeneous structure to controlled porous structure)

  46. Manufacture components with outstanding mechanical properties LENS Ti-6-4 chosen by Tensegra Inc. as the onlyprocess that could give the required properties for a spinal implant Tested in three cows in-vivo for one year Passed all structural integrity, osseointegration and functionality tests Insert into production flow LENS material machines, peens, blasts exactly as conventional material LENS Medical Applications: Structural Components

  47. LENS Medical Applications: Integration Surfaces • Improve osseointegration with a LENS-deposited coating • TCP • HA • Mixtures with Ti and other metals • Rough surfaces • Open surfaces TriCalcium Phosphate + Ti for bioactivity

  48. LENS Medical Applications: Mass Customization • Mass customization of orthopedic implants • MRI data drives CAD model • LENS process part built to fit • Reduce patient recovery time and trauma • Improve longevity of implant

  49. LENS Medical Applications: Alloy Design • Medical Material Discovery • Many structural alloys are designed for aerospace, not medical applications • LENS process enables the rapid discovery of new alloys by on-the-fly mixing and layer-by-layer manufacture of new materials • Beta-titanium alloys developed with improved wear resistance and modulus for improved bone matching Ti-35Nb-7Zr-5Ta with 2% boron reinforcement

  50. Summary

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