AM Opportunities at UTAS

Transcription

1 AM Opportunities at UTAS Robert Bianco, PhD Manager, Materials R&D July16, 2015 This document is approved for public release. This document or file does not contain export controlled technology or technical data.

2 UTAS OPPORTUNITIES IN AM Outline UTC/UTAS Overview UTAS Opportunities and Strategy AM Methodology Development Lab Design for AM Process Modeling External Funding Future Needs 2

3 UTC BUILDING & INDUSTRIAL SYSTEMS UTC PROPULSION & AEROSPACE SYSTEMS 3 4/15/2015

4 UTC PERFORMANCE Sales: Type & Geography 2014 net sales $65.1 billion TYPE Commercial Aerospace 35% 45% Commercial & Industrial Aftermarket 58% 42% Military Aerospace & Space 20% Original Equipment Manufacturing GEOGRAPHY Other 15% 0% Asia Pacific 20% 38% United States 27% Europe 4 2/24/2015 4/15/2015

5 8 strategic business units ~42,000 employees ~150 locations July 2012 United Technologies formed UTC Aerospace Systems THIS DOCUMENT OR FILE CONTAINS NO EAR TECHNOLOGY OR ITAR TECHNICAL DATA. 5 2/24/2015 4/15/2015

6 UTC AEROSPACE SYSTEMS Global program execution Airbus A350XWB Airbus A320neo Gulfstream G650 Mitsubishi MRJ Bombardier Global 7000/8000 Bombardier CSeries COMAC C919 Irkut MC-21 Embraer E2 Embraer KC-390 Airbus A400M Lockheed F-35 Sikorsky CH-53K 6 4/15/2015 6

7 Pilot/Crew Seats Cockpit Controls Vehicle health management Air Management Systems Delighting customers Ice Detection/ Prevention Actuation Systems Exterior/Interior Lighting Sensors Fuel Systems Nacelles Pylons Engine Controls & Components Landing Gear Cargo Systems Wheels & Brakes Power Generation & Distribution Systems Escape Slides Fire & Overheat Protection Systems Global, 24/7 service Game-changing technologies Committed to perfect delivery and quality Right attitude 7 4/15/2015

8 UTC AEROSPACE SYSTEMS (UTAS) 8 SBUs & 87 product lines Aerostructures Nacelle systems Flight control surfaces APU tail cones Acoustic materials, coatings & structures Actuation and Propeller Systems Primary and secondary flight controls Helicopter rotor actuation Nacelle actuation Utility actuation Propeller systems with composite blades and electronic controls Cockpit controls Cabin equipment Trimmable Horizontal Stabilizer Actuators (THSA) Sensors & Integrated Systems Air Data & SmartProbe Systems Engine sensors and sensing suites Fuel level and management systems Fire detection and protection systems Guidance, navigation and control Health management systems Ice detection and protection systems Inertial sensors and rate gyros Mission data recorders Potable water systems Rescue hoist and cargo winches Smartdisplay EFB systems Specialty heated products Temperature sensors Video surveillance systems Landing Systems Landing gear Wheels Brakes Brake control systems High temp composites ISR & Space Systems Reconnaissance systems Airborne laser warning Ground systems NASA space suit/life support systems Environmental monitoring and control, mechanical systems, thermal control systems Interiors Cargo handling systems Evacuation systems Propulsion systems Specialty seating Lighting systems Engine & Environmental Control Systems Environmental control systems Bleed air systems Cabin pressure systems Ventilation systems Inert gas generating systems Electronic engine controls Engine control systems Engine and nozzle actuation Gearboxes Fuel metering units Fuel pumps Aero gas turbine components Airfoils and rotating components Drive shafts and couplings Electric Systems Generation Primary distribution Secondary distribution Emergency power, motors and drives 8

9 ADDITIVE TECHNOLOGY ROADMAP Cross-functional team across SBUs Part Families Fuel Injectors Impellers & Rotors Housings Brackets Heat Exchangers 9

10 BUSINESS CASE Perceived Benefits Lead time reduction Part count reduction Buy-to-fly reduction Manufacturing cost reduction Optimized design for performance/weight reduction Material and energy usage reduction 10

11 ADDITIVE MANUFACTURING Additive Manufacturing Technologies Powder Bed Fusion Powder Deposition Consolidation Extrusion Printing Hybrid Laser Powder Bed Laser Ultrasonic FDM Direct Write Electron Beam Melting Cold Spray Materials of interest Nickel alloys Titanium and aluminum alloys Cobalt and iron alloys Thermoplastics 11

12 ADDITIVE MANUFACTURING Development Lab Thermal Processing Additive Manufacturing Microscopy Mechanical Test Analytical Chemistry Lobby Materials lab capabilities upgraded and enhanced including new AM cell 3DSystems ProX 300, L-PBF machine and Fortus 450mc FDM machine installed 12

13 ADDITIVE PROCESS FLOW Powder Quality Build Parameters Design Allowables Part Builds HIP & Heat Treat Quality & Inspection Finishing Rig & Engine Tests 13

14 ADDITIVE MANUFACTURING OEM parts Part design and builds Material characterization Post processing and impact on properties Fuel Injector Impellers/Rotors Process control & variability NDE and Measurement Techniques Non-destructive methods Designing for additive manufacturing 14

15 ADDITIVE MANUFACTURING Laser additive repair Repair of damaged fuel nozzles Integrated 3D scan, repair and CNC machining Characterization of mechanical behavior and properties Source: Rapid 2012, Donovan (UTC Aerospace Systems), Xue & Li, NRC Canada 15

16 DESIGN FOR ADDITIVE Topology Optimization Design Space FEA Model Optimized Geometry Topology optimization determines load path for minimum material configuration Rig testing confirms FEA analysis of strength margin Up to a 50% weight savings possible 16

17 PHYSICS BASED MODELING Developing physics based understanding of key process parameters Defining impact and control of parameters to guide spatially varying geometry Using validated models to run virtual DOEs for new part families 17

18 EXTERNAL FUNDING UTC wins AFRL Additive Heat Exchanger contract AFRL / America Makes selects UTC team for additive heat exchanger Focus on fundamental understanding of process parameters, surface finish and HX performance Team: UTRC (prime); subcontractors - UTAS, P&W, UCONN, Stratonics, and 3DSIM UTAS: HX design tool, builds and validation UTRC: Modeling, Performance testing Residual stress and distortion Key process CTQs; Scan strategies Melt pool monitoring Thermal imaging 18

19 TECHNOLOGY NEEDS Near Term (CY16) Advanced NDT of AM Built Parts For Internal Defects For Entrapped Powder Strategic Material Property Databases High-Strength Steels Fine-Grained, High Temperature Alloys High Deposition Rate AM Techniques Without Loss in Precision and Tolerance Control 19

20 TECHNOLOGY NEEDS Near Term (CY17 and beyond) Process Modeling for Improved Quality Process/Microstructure/Performance Relationship Grain Size/Morphology Control Process Monitoring for Consistent Builds LPBF Process Certification Strategic Material Property Databases High-Strength Al Alloys High-Strength Ti Alloys Sustainable Supply Chain Nadcap Accreditation 20

21 QUESTIONS 21

22 UTAS POINTS OF CONTACT Innovation and Technology Agnes Klucha Program Manager, Research & Technology Partnerships Office: (860) Robert Bianco Manager, Materials R&D Office: (860)