1. ADDITIVE MANUFACTURING PROJECT CLUSTER MEETING TOPIC: AM for Metal Parts Fundació CIM C/Llorens i Artigas, 12 Parc Tecnològic de Barcelona Barcelona, Spain 2 May 2016 Dr. Prabir Chaudhury Technical Director, Metals Technology Exova PLC

2. Development of AM Metal Parts for Broader Growth Advantages of additive manufacturing of metal parts have been established Many metal AM methods, machines, and manufacturers are available in the industry Not all machines and methods produce same quality of products Microstructure and properties are not well developed for designers to select AM metal parts for applications Testing and qualification protocols and standards are at its infancy AM specific materials have not been developed for improved quality AM part surfaces are adequate for net shape applications Cost of AM metal parts is very high – specialized powders for AM are required

3. Exploitable Results (ERs) Design allowables will enable design engineers to select AM metal parts AM metal properties are being developed in various programs to compare with existing materials and processes In order to develop AM as a main stream manufacturing process organized development of design allowables with statistical significance need to be conducted Testing and qualification protocols and standards for raw material, machine, process, and products will help wide-spread application of AM metals Current testing is limited to R&D and the results are promising, but testing and qualification methods are not standardized or uniform Standardized testing and qualification protocols will enable AM metal parts to be used in service rapidly Surface finish improvement will enable manufacturing complex, net shape parts Current processing limitations produce metal part surfaces that require costly machining In-process or cost effective post processing is needed for direct application of AM metal parts in service Use of low cost metal powders will significantly reduce the cost of AM metal parts Irregular shape powders are inexpensive but not suitable for current AM methods Development of machines and processes that can use inexpensive raw materials will make AM metal parts more attractive.

4. Design Allowables and Database/Handbook Develop a compendium of mechanical, chemical, and microstructural data related to most promising (exploitable) AM processes Generate statistically significant (A-basis/B-basis) mechanical properties with microstructural data for selected AM processes Rate AM metals for corrosion resistance and chemical properties Potential customers OEMs in Aerospace, Oil and Gas, and all other industrial sectors Government Agencies and Military Services with stringent and special requirements First and second tier designers, suppliers, and manufacturers Customer Benefits Ability to design and manufacture complex, unitized parts Reduce lead time and overall system cost Improved readiness to market demands.

5. Design Allowables and Database/Handbook Technological Readiness Level 5 Technology for manufacturing has been demonstrated in a limited level but needs to expand Milestones in the TRL progression up to TRL9 Select qualified processes and machines Generate statistically significant mechanical, microstructural, and chemical (corrosion) properties Develop a database (similar to MMPDS) with all necessary properties for design Demonstrate by designing and manufacturing complex, unitized products Main technical challenges in this result Selection of exploitable AM processes and machines Generation of data that are relevant to the design community at various industries Time to market (Mth/yr):2 – 5 years per metal IPRs - Have you protected or will you protect this result before disclosing it? How? When? No This effort will eliminate internal databases and promote open knowledge base for rapid growth of the industry

6. Design Allowables and Database/Handbook IPRs Have you protected or will you protect this result before disclosing it? No How? N/A When? N/A

7. Testing and Qualification Protocol Standardized testing and qualification protocol and methods will enable rapid growth of AM metal part design and production Current property measurements are not suitable for qualification, implementation in service Develop an industry wide testing and qualification protocol for various AM processes and resulting products Potential customers All OEMs who design, test, qualify, and implement products in service Government and military services who require verified technologies for their applications AM suppliers who manufacture the parts and components Customer Benefits Ability to introduce AM products in service with little or no risk. Consistency among the part manufacturers and OEMs for AM process comparison for their applications

8. Testing and Qualification Protocol Technological Readiness Level 5 Technology for manufacturing has been demonstrated in a limited levels in specific industry but needs to be able to introduce products in service Milestones in the TRL progression up to TRL9 Generate AM process and machine specific testing and qualification protocol Demonstrate the testing and qualification protocol Develop requirements and specifications for various AM processes and products Main technical challenges in this result Obtain consensus among the OEMs, manufacturers and accreditation and standards bodies Time to market (Mth/yr):2 – 3 years IPRs - Have you protected or will you protect this result before disclosing it? How? When? No

9. Testing and Qualification Protocol IPRs Have you protected or will you protect this result before disclosing it? No This will become required standard the IPs have to available to all participants in the industry How? N/A When? N/A

10. Surface Finish Improvement Adequate surface finish will take full advantage of manufacturing complex, net shape metal parts Current production methods in AM industry cannot produce satisfactory surface finish Developing in-process or cost effective post processing methods to improve surface quality will exploit full benefit of AM Potential customers All OEMs who design and implement products in service AM suppliers who manufacture the parts and components Customer Benefits Ability to introduce products in service without time consuming and costly post processes. Ability to increase product durability and reliability in service

11. Surface Finish Improvement Technological Readiness Level 2 Basic concepts are being explored in research level by exploring the possibility of using finer powders and other process improvements Milestones in the TRL progression up to TRL9 Explore in situ surfacing methods in various AM processes Make post process surfacing methods commercially viable Demonstrate the surface finish produced has adequate surface quality Main technical challenges in this result Develop additional features in the existing machines to finish the surface in situ Explore and develop cost effective post processing methods Time to market (Mth/yr): 4 – 5 years IPRs - Have you protected or will you protect this result before disclosing it? How? When? No

12. Surface Finish Improvement IPRs Have you protected or will you protect this result before disclosing it? No, but will protect the results before disclosing it How? Through patenting When? After successful demonstration of technologies.

13. Use of Low Cost Raw Materials Current powder metals used as raw materials require specific properties Current powder metals are expensive because they must possess good flowability in solid state, uniformly spherical and surface blemish free Low cost powders are irregular in shape, their use will decrease raw material cost significantly Potential customers All OEMs who design and implement cost effective products in service Government and military services who require cost effective solutions for their applications AM suppliers who manufacture the parts and components Customer Benefits Lower overall cost of final products.

14. Use of Low Cost Raw Materials Technological Readiness Level 2 Technology for manufacturing has been conceptualized but there is no demonstrated proof of concept Milestones in the TRL progression up to TRL9 Develop machines that are capable of using irregular shape and low cost powders Demonstrate the ability to use low cost powders for various applications Certify machines with demonstrated capability Main technical challenges in this result Develop new or modify current machines to use other technologies for use of low cost irregular powders. Time to market (Mth/yr): 5 - 6 years IPRs - Have you protected or will you protect this result before disclosing it? How? When? No

15. Use of Low Cost Raw Materials IPRs Have you protected or will you protect this result before disclosing it? No, but will protect before disclosing it How? Patents When? After demonstration of technology in laboratory scale

16. Expressions of Interest 1.Development of new AM specific materials (5 projects) AM specific Al, Ti, Ni, Cr, and Co alloy compositions for AM industry (M1-US-QUESTEK) Nanomodified and nano particle embedded Ti-6Al-4V alloys (M14-EU-NANOTUN3D) 2. Characterization methodology and qualification of raw materials (6 projects) Characterization of Ti6Al4V powder and parts (M6-SA-MEDAERO) Characterization of superalloy wires (M7-MX-FRISA) Material, process, machine, and product certification and qualification for AM RepAIR processes (M11-EU-RepAIR) 3.AM Processing Technology Development (7 projects) Qualified process chains and validated post-processing treatments for SLM Ti-6Al-4V parts (M6-SA-MEDAERO) AM production Ti- and Ni-based alloys, NeFeB and other magnetic materials (M10-EU-REPROMAG) Selection and optimization of AM processes for Ti printed parts (13-EU-AATID) 4.Manufacturing process tools (3 projects) Hot sheet forming and reconfigurable tooling production by AM (M5-SA-FORMING) Cladding, repair, and modification of hot forging tools by AM (M7-MX-FRISA) 5.Workforce development, education, knowledge base and property database for AM (6 projects) Knowledge/educaional material and training curricula for AM (GT2-SA-EDUCATE) Workforce (Employee) training on AM (GT6-SA-HYGIENE) AM Roadmap and database (GT11-EU-FOFAM) and AM Knowledge database (GT12-EU-MANSYS)