Additive Manufacturing at GE

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Imagination at work.

Greg Morris

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Page 3 7/27/2014

Pre-GE Acquisition

MTI & RQM



Founded 1994



Introduced DMLM to NA in 2003



135 employees



Services included:



Engineering & Design



Additive (Metals/Polymers) (25 additive machines)



Post-Processes (Machining, Thermal Processing, Finishing)



Collaborations/JV’s…i.e. MicroTek Finishing w/BinC, etc.

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Page 4 7/27/2014

Additive

Development

Center

- GEA focus

- Other GE

- Select Externals

Additive

Lean Lab /

Pilot Production

- Low rate initial production

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Page 5 7/27/2014

Manufacturing Technology Development

TRL / MRL 0

TRL / MRL 3

TRL / MRL 6

TRL / MRL 9

ID New

Technologies

Technical

Feasibility

Support

Production

Develop

Technologies

Mature

Technologies

GRC

Additive

Development

Center (ADC)

Additive

Lean Lab

(ALL)

Production

Material Development

Physics Models

Early Process Dev

Material Development

Machine Development

Process Development

---

Test Fixture/ Tooling Mfg

Prototype Manufacturing

Test Article Manufacturing

Pre-Production Mfg

Early Production Mfg

Product VSE

Production Process Dev

Low Rate Manufacturing

Final Production Site (Auburn, AL)

High Rate Manufacturing

Entitlement Cost

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GE Proprietary Information

3D CAD Model

AM Process

Thermal

Processing

Post Processing

and Inspection

Final Part

Prep for Process

Basic Process (DMLM)

Additive

Manufacturing

at GE | July

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GE Proprietary Information Export Authorization, ECCN: 9E991, NLR

Types of Additive

Rapid Prototyping? Additive Manufacturing? 3D Printing?

Photo Courtesy: EOS

Photo Courtesy: Stratasys Photo Courtesy: Stratasys

Photo Courtesy: Stratasys

Photo Courtesy: 3D Systems Photo Courtesy: Arcam

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Polymers - SLA

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Polymers - SLS

Photos Courtesy: EOS

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Polymers - FDM

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Polymers - PolyJet

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Metals

Photo Courtesy: ORNL

Photos Courtesy: Within Labs

Photo Courtesy: EOS

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Nano Additive Mfg.

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Other 3D Printing

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GE Aviation Additive:

SLA: (2) 500’s, (2) Vipers

(3) ProJet 3500

ARCAM: (8) A2(xx)

FDM: (1) Fortus 900

PolyJet: (1) Connex 500

EOS: (11) M270’s

(4) M280’s

_{SLM: (2) 250HL}

Photos Courtesy: 3D Systems, Stratasys, EOS, SLM

C-L: (1) M2

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GE Aviation Additive Support:

Multi axis milling

Multi axis Turning

Airflow test stand

CMM/Laser Scan

5-axis EDM Hole Drill

Wire EDM

Extrude Hone

CAD Modifications

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Production Prep:

DMLM: (7) M270’s

Thermal Processing: (1)

Vacuum Stress, (1) HIP

Powder Size Analysis

Inspection

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Instrument Probe - 2007

• Successful builds (no crashes)

• Less cost to produce

• Higher test life

• More accurate probes

• Lower number of probes

required

• Better data collection

• Shorter fabrication time

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Design For Additive

Makers Guild

Corporate initiative to gain exposure and

expertise in the world of 3D printing

Learn about:

• Build orientation

• Shape capability

• Support structure

Original design

Example entry

Crowdsourcing Design Challenge

Public challenge

to find new

design strategies

for additive

manufacturing

150 entries in less

than 30 days

Top designs will

be manufactured

and tested by GE

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Design Challenge and the Potential of

Additive



Tapped into 750k+ online community



Over 700 entries received



Many submissions over 80% weight

reduction

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Parts Grown and Tested

7/27/2014

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Inco

718 Inco

625 316L

SS

W

Ti64

MS-1

Cu

AlSi10

_Mg

6061

T6

CoCr

Hast

X

17-4

PH

SS

15-5

Ti 6242

• Super Alloys (2005)

• Many similar to wrought strengths

• Some materials characterized

• Large opportunity for novel alloy

development

Material Properties Drive Applications

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Material Properties Drive Applications

Wrought

DMLM

Horiz

ontal

V

ertic

al

Melt Pool Directionality Vertical Grain Growth

Similar to Wrought

Isotropic / Homogeneous

Typical Equiaxed

Grain Structure

Solution Heat Treatment 40 60 80 100 120 140 160 180 200 DMLS - V DMLS - H Wrought

Low WroughtHigh

YS (ksi) "UTS (ksi)"

18 22 26 30 34 38 42 DMLS - V DMLS - H Wrought

Low WroughtHigh

Elongation (%) "Hardness (HRC)"

ASTM

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Material Properties Drive Applications

Wrought

DMLS

Horiz

ontal

V

ertic

al

Typical Alpha + Beta Widmanstatten Structure

Finer than DMLS or EBM

EBM

Similar to DMLS Alpha on Deposition Layer

100 120 140 160 180

YS (ksi) "UTS (ksi)

ASTM

0 5 10 15 20 25 30 35 Elongation (%) "Hardness (HRC)

ASTM

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Machining

Special

Processes

Surface

Finishing

Metallurgical

Lab

Thermal

Processing

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EBM ‘Cake’ – Limit of Internals

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How GE Aviation is Using Additive

Metals

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Leveraging AM – NPI Hardware

Fuel Swirlers



7 th

_{set of HPT’s in 6 years}



Substantial cost and lead time reduction



Design refinement options



Land-based Gas Turbine Engines



90 parts in (3) months



Met testing timetable

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DMLM Design Advantage

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DMLM Fuel Nozzle Design History

Begin TAPS

Development

CoCr DMLM Material

Development

DMLM for

prototype testing

GEnx certifies

Traditional Mfg.

22 piece construc.

DMLM supply

chain acquisition

LEAP FETT

2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

2011

2012

2013

LEAP 1 piece

DMLM Nozzle

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LEAP 56 Next Generation Fuel Nozzles



19 Fuel Nozzles in each engine

– 40K full production



20 pieces to 1



5x durability improvement



25% weight reduction

(compared to GEnx)



Fuel Nozzle is a very efficient

heat exchanger

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Exploring Optimized Structures

Optimized Result: 30% less weight

Original

Re-designed (conceptual)

• Combine parts to eliminate weight

• Performance gains

• Maintenance reduction

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EXPERIENCE ON EBM - TiAl

Advantages of the EBM process:



low level of internal defects, no typical casting

defects, therefore low scatter in material properties



homogeneous microstructure



very fine grain size, leading to good material properties, in particular fatigue

properties, and no need for grain refinement



no limitations in chemical composition



no residual stresses due to high process temperature



little waste material: powder can be recycled as the oxygen pick-up is very

low

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Accelerating Adoption

Present 2014 2016 2018+

Process

Variation

Validation

Tools

Surface Finish

Growing Acceptance with Continuous Innovation

Accepted Industry

Standards

Process

Monitoring

Diversified

Materials

Higher Capacity

Machines

Application

Specific Machines

Predictive

Analysis Tool

Gradiated

Materials

Accepted

Best Practice

Process

Automation

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Gaps and Challenges

• Rapid Qualification

& Materials Database

• IP: Rights & Tracking

• NDT / Internal Flaw detection

• Supply Chain:

Development & Protection

• Available Materials

• Technician Skill Level

General

Process Specific

• Surface Finish

• Distortion

• Build Volume

• Throughput

• Process Monitoring and

(50)

Supply Chain Shift?

From

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More Local?

Field Operation



Substantial supply chain

challenge in remote locations



Spare / Repair parts on-site?

(52)

Parts Inventory



Local ability to grow parts?



Controls inventory



Balance inventory with

needs/delivery



Flexibility for design changes (no

order minimum)

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Broad Trends



Challenging IP landscape



Further consolidation (all areas)



Increased adoption of technologies



Accelerating innovation



New business models

0 20 40 60 80 100 120 140 160 2012 2013 2014 2015 2016 Applications IP Alloys

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Creators &

Pioneers

Adopters

Early

Majority

Primary

Secondary

Majority

Holdouts

What Phase Are We In?

(55)

~$10.5 Trillion

Global Mfg. Output:

Additive’s Potential:

:



~$2.2 Billion Professional

Industrial Additive Market



~0.02% of total global Mfg.

output

(56)

Imagination at work.