Large format additive manufacturing with direct energy deposition (DED) technology
Project challenges
In recent years Additive Manufacturing has become a prominent technology in the manufacturing of complex 3D structures and there are several types of AM technology capable of building a wide variety of various component shapes and sizes.
Business challenge
Process Innovation
Sector
Aerospace
Technology or capability
Laser Processing
Project Challenges
In recent years Additive Manufacturing has become a prominent technology in the manufacturing of complex 3D structures and there are several types of AM technology capable of building a wide variety of various component shapes and sizes. Directed Energy Deposition (DED) is conceptually, a relatively simple but very innovative technique that allows the building of large-scale 3D structures and functional components that can be applied in multiple sectors, such as aerospace, defence, marine, transport and even space. It can also be used for repair and refurbishment purposes.
Commercially available systems for DED are limited in number and the programming and control, software systems can be disjointed in nature with regard to the joining up of the process steps. this can make the process of designing and manufacturing somewhat challenging.
MTC's Solution
The MTC proposed the building of a marine propellor out of 316L stainless steel using a Fanuc multi-process DED cell consisting of 3 robotic arms with a build envelope of 1m3.
The propeller structure was programmed using NX Manufacturing multi axis deposition CAD/CAM software.
The propeller was built using an integrated Fronius cold metal transfer (CMT) technology, with the torch mounted on a Fanuc M20IA robot and coaxial wire feed working in tandem with a rotating fixture table.
By utilising the multi axis fixture table (manipulator) and “coordinated motion” between it and the robot. It was possible to build the propeller without any support structures.
The outputs from this project represent a milestone in the development of DED at the MTC, progressing from small-scale, single-feature builds looking at process fundamentals, to demonstrating the combined learning and expertise gained through a number of past projects by building a large-scale demonstrator. This is an important step in building our own capabilities for DED, as well as building justification for future investments for both equipment and internal projects to support industrial programmes looking to produce large parts using this process.
By David Gilbert, Technology Manager, MTC
The Outcome
- The MTC successfully built a marine propeller structure out of 316L stainless steel material with a build envelope of approximately >1m3
- The build was done without any support structure
- The MTC has successfully demonstrated the technology at TRL level 4/5 with this demonstrator
Benefits to the Client
- The ability to manufacture complex geometrical 3D metal structures using DED technology for components with a volume of 0.5t / >1m3
- The new capability opens up other opportunities and potential for supporting other applications for complete component manufacture, but also for repairs for components, whether originally manufactured via DED or by more conventional means such as machining or casting.
- Potential to drastically cut manufacturing lead times compared to conventional means of manufacture.
- Eliminates the requirement for the manufacture of expensive dies or mould tools to produce the component, or the excessive creation of material waste associated with machining from solid billet.
