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Plgh-1hroughpuL luncuonal MaLerlal
ueposluon uslng a Laser PoL-Wlre rocess

3 !une 2014
!lm McCumn-Cawley
rofessor and ueparLmenL Chalr, MaLer. Scl. & Lngr.
Case WesLern 8eserve unlverslLy
cawley[case.edu
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ro[ect 1eam
Consumable
Supply
rocess
Cpumlzauon
rocess/
roperLy
CharacLerlzauon
Lnd-user Llnk
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CosL - 8eneL Analysls for Lhe ueparLmenL of
Lnergy

Slldes from 8ob lvesLer & 1ony 1ublolo

u.S. ueparLmenL of Lnergy -
Advanced ManufacLurlng Cmce
(formerly lndusLrlal 1echnologles rogram)
8oom 3l-063, MS LL-2l
1000 lndependence Ave, SW
WashlngLon, uC 20383


Addluve and Lnergy: 8ackground
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Advanced ManufacLurlng Cmce alms for
economy-wlde llfecycle lmpacLs
8. lvesLer & 1. 1ublolo, uCL

1 quadrllllon 81us equlv. energy ln 36 MM meLrlc Lons of coal

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keduced product ||fe-cyc|e energy consumpnon Lhrough
Addluve ManufacLurlng:
- Mater|a|s - uramaucally reduces use of maLerlals wlLh hlgh
embedded-energy conLenL
- Manufacture - 8eplaces energy-lnLenslve manufacLurlng
processes
- 1ransport - 8educes lnvenLory of parLs LhaL need Lo be
sLored and LransporLed
- Use - 8educes fuel/energy consumpuon durlng producL
use
- D|sposa| ] ke-use - Allows remanufacLurlng of parLs, uslng
a fracuon of Lhe energy requlred Lo make new parLs
Addluve and Lnergy
1
hup://www1.eere.energy.gov/manufacLurlng/pdfs/addluve_manufacLurlng.pdf
8. lvesLer & 1. 1ublolo, uCL

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keduced product ||fe-cyc|e energy consumpnon Lhrough
Addluve ManufacLurlng:
- Mater|a|s - uramaucally reduces use of maLerlals wlLh hlgh
embedded-energy conLenL
- Manufacture - 8eplaces energy-lnLenslve manufacLurlng
processes?
- 1ransport - 8educes lnvenLory of parLs LhaL need Lo be
sLored and LransporLed
- Use - 8educes fuel/energy consumpuon durlng producL
use
- D|sposa| ] ke-use - Allows remanufacLurlng of parLs, uslng
a fracuon of Lhe energy requlred Lo make new parLs!
Addluve and Lnergy
MusL be equlvalenL maLerlal properues,
Sub[ecL of pro[ecL led by !. !. Lewandowskl
8euse ls Lhe mosL powerful of Lhe eco-38's,
Sub[ecL of pro[ecL led by u. Schwam
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Case SLudy (1) - MonlLor Arm
Atkins Project UK government and industry consortium
promoting additive manufacturing has several LCA case
studies:
Aluminum monitor arm (aerospace) manufactured by 3 pathways:
Manf. athway CNC mach|n|ng Se|ecnve Laser Me|nng -
1opo|og|ca||y opnm|zed
Se|ecnve Laser Me|nng -
Lamced
A| |nput (kg) 2.91 0.33 0.38
I|na| part mass (kg) 0.86 0.34 0.39
L|fe cyc|e stage
kaw mater|a|s (MI) 639 116 128
Manufacture (MI) 9 30 33
1ransport (MI) 90 23 31
Use (MI) 690,113 271,188 311,960
Lnd of ||fe (MI) 1 0 0
1C1AL (MI) 690,8S2 271,380 312,174
uomlnaLed by
L = mgh
8. lvesLer & 1. 1ublolo, uCL

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Case SLudy (2) - ump Pouslng
Automotive diesel engine pump housing (Delphi)
manufactured by various pathways and materials:
Manf. athway Grav|ty d|e casnng - A| Se|ecnve Laser Me|nng - A| Se|ecnve Laser Me|nng - SS
316L
Mater|a| |nput (kg) 2.00 0.31 0.89
I|na| part mass (kg) 1.03 0.21 0.39
L|fe cyc|e stage
kaw mater|a|s (MI) 322 68 72
Manufacture (MI) 3 30 92
1ransport (MI) 48 7 16
Use (MI) 342 77 220
Lnd of ||fe (MI) 1 0 0
1C1AL (MI) 718 182 400
Again, SLM pathways show energy savings in Raw Materials through less scrap, Use Phase through
lightweighting; Manufacturing energy is higher.
SLeel for half Lhe
prlce of alumlnum
8. lvesLer & 1. 1ublolo, uCL

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roblem SLaLemenL: !"#$%& ())"*+$ ,(-./(%&.#"-0 1/ ,$&(2 3(#&4 "4 2","&$) 56
%14& (-) (+("2(5"2"&6 1/ %1-4.,(52$47 5."2) *,$47 (-) 4&$$3 &$,31#(2 (-) 43(*(2
&8$#,(2 0#()"$-&4 %1,3#1,"4"-0 ,$&(22.#0"%(29,"%#14&#.%&.#(2 %1-&#12:
Cb[ecuves: ;4&(52"48 &8$ #15.4&-$44 (-) #$2"(5"2"&6 1/ &8$ <(4$# =1& >"#$ ?<=>@
3#1%$44 (4 ( +"(52$ ())"*+$ ,(-./(%&.#"-0 ?AB@ &$%8-12106 &8(& %(- 5$ .4$) "-
=$(+6 C(5#"%(*1-7 A$#143(%$ (-) ;-$#06 4$%&1#4.
uellverables: D@ !$,1-4&#(*1- 1/ <=> E"&8 *&(-"., (-) -"%F$2 (221647 1-$ 1/
E8"%8 5$-%8,(#F$) (0("-4& GHCI< 3(#&4J K@ !$L-"*1- (-) "-"*(*1- 1/
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%1-&#127 (-) 3$#,"&4 "-%2.4"1- 1/ ,$&(4&(52$ 38(4$4 /1# .-"P.$ ,"%#14&#.%&.#$4:
Laser not-W|re ro[ect Cverv|ew
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Wlre feed - hlgh
deposluon raLes
owder
8ed
8lown
owder
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lused ueposluon Modellng (reprap.org) MeLal lnerL Cas Weldlng (weldguru.com)
W|re Ieed - po|ymers & meta|s
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Ireeform We|d|ng |s not new
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MIG We|d|ng n|gh Speed V|deo
hups://www.youLube.com/waLch?v=ullS!1C4vsg
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What |s spec|a| about LnW
WC ln nl



316L




Cr-Carblde
(Cr
3
C
2
ln nl-Cr)
lnconel 623
Slngle ass
lnlual sLrlnger (slngle bead) and weaves (bulld sLyles)
of nl 623 on plaLe
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1he goal ls developlng AM for appllcauons LhaL requlre
sophlsucaLed meLallurglcal conLrol.
Cll and Cas SecLor:
nlckel alloys as a claddlng for casLer rolls, chocks and houslngs LhaL are
sub[ecL Lo harsh envlronmenLs and corroslon. Lxlsung meLhods are
generally:
! llmlLed Lo aL horlzonLal surfaces,
! produce undeslrable levels of poroslLy due Lo ux conLamlnauon,
! are labor lnLenslve,
! requlre hlgh sklll operaLors, and
! suer dlluuon eecLs for overlays.

LPW-AM wlll be demonsLraLed as an alLernauve wlLh exlsung Llncoln
LlecLrlc cusLomers.
1echno|ogy 1rans|non Approach
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D||unon I||ustranon
aul uenney, ASM lnLernauonal AM Symp., May
2014
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Aerospace SecLor: 1lLanlum forglngs for sLrucLural alrframe
componenLs are drlven by mechanlcal properues such as
durablllLy and damage Lolerance are paramounL.

! 1yplcally processes are hlgh buy-Lo-y wlLh assoclaLed hlgh cosL,
maLerlal consumpuon, and energy cosLs.
! LPW processed uLanlum Lyplcally exhlblLed beLa mlcrosLrucLures LhaL
wlll be demonsLraLed as comparable Lo aerospace componenLs
manufacLured wlLh beLa annealed alloy.

1echno|ogy 1rans|non Approach
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ro[ect 1eam
lnform
auon LWP l, process knowledge,
equlpmenL
1lLanlum sheeL & wlre
Mouon conLrol & soware
developmenL
MlcrosLrucLure & properLy
characLerlzauon, slmulauon
nl-alloy sheeL & wlre
Laser slnLered
conLrols
Appllcauon englneerlng
rocess evaluauon, parL
& properLy
characLerlzauon
roperLy
characLerlzauon

a
r
L
s

arL geomeLry
arL & properLy
characLerlzauon arLs
Lnd user
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arLs
arLs
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lnformauon
National Additive Manufacturing Innovation Institute
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Susta|nab|||ty Approach
Lnergy, MaLerlal, and rocess Lmclency measures wlll be quanued relauve Lo
convenuonal processes and alLernaLe AM processes.

rellmlnary calculauons lndlcaLe LPW oers speclc bulld energy cosLs (meLal
deposlLed per energy expended) 4 Lo 6 umes hlgher Lhan some commerclal AM
meLhods. 1hls needs Lo be rlgorously evaluaLed uslng comprehenslve accounung.

Calculauons lndlcaLe Lhe energy consumpuon ln Lhe hoL-wlre process are sull
10 umes Lhe adlabauc melung of meLal.
1he advanLages of laser hoL wlre ln Lerms of speclc energy use per mass of meLal
deposlLed was a drlvlng force for lLs developmenL. ConLrlbuung facLors lnclude:
use of a wlre relauve Lo a powder bed, paruuonlng Lhe energy beLween an
exLernal clrculL and Lhe laser, shorL dwell ume above Lhe melung polnL, low peak
LemperaLure, and reducuon ln volume heaLed.
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Susta|nab|||ty Approach
Lnergy, MaLerlal, and rocess Lmclency measures wlll be quanued relauve Lo
convenuonal processes and alLernaLe AM processes.

Low peak LemperaLures and mlnlmlzed ume aL LemperaLure have been observed
Lo ellmlnaLe Lhe need for shleldlng gases wlLh ferrous alloys. 1hls reduces boLh
balance of- planL and operauonal demand on energy-lnLenslve compressed hlgh-
purlLy gases.

8y exerung sumclenL conLrol over Lhe meLallurgy durlng parL growLh lL wlll
posslble Lo avold posL-processlng heaL LreaLmenL Lo conLrol mlcrosLrucLure and
relleve sLress.

Cne of Lhe chlef Lechnlcal goals of Lhe pro[ecL ls Lo employ Lhe LPW process Lo
reduce ln Lhe buy-Lo-y rauo, meanlng LhaL Lhe amounL of lnpuL maLerlal needed
Lo manufacLure sLrucLurally crlucal aerospace componenLs ls dramaucally reduced.
1hls LranslaLes lnLo a slgnlcanL reducuon ln machlnlng, and assoclaLed waLer and
energy.

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1echn|ca| Approach
!"#$%& !"#$%& ()#$%& !"*$%& +,-$%& +,.$%& (,/$%& 01)$%& 234$%& 567$%& 813$%& +"-$%9 :1;$%9 !"#$%9 ()#$%9 !"*$%9 +,-$%9 +,.$%9 (,/$%9 01)$%9 234$%9 567$%9
2#/"-<=1 " ><3>$6? @11A-/ "-B 36@@<4 46 @11A-/ A@1CDC3E1B,.1C
8171.6) " @<.1C46-1 )."- "-B )#6F134 B1.<71#";.1 )."-
2;4"<- @"41#<". G6# 41C4 )#6/#"@
H$I !")C G6# B<.,A6- "-B )1-14#"A6- )#6J.1
K,<.B$,) G6# 36##6C<6- 41CA-/
!<3#6C4#,34,#1 E141#6/1-1<4* "CC1CC@1-4 6G ;,<.B$,)C
L1)1"4";<.<4* "-B L1)#6B,3<;<.<4* (-".*C<C
H")1# )#1C1-4"A6-C "4 :";413EM 5(NO PQ%9 "-B !0RS
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H$I !")C G6# 2D5 )<3>$,) "-B 4E#6,/E$),4
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Z1;<-"# G6# 1B,3"A6- 6G 41"@ @1@;1#C 6- B<?1#1-4 @"41#<". C*C41@C
Z6#> G6#31 4#"<-<-/ T!6B,.1%[ X@)6#4"-31 6G E</E 4E#6,/E),4V
Z6#> G6#31 4#"<-<-/ T!6B,.1 P[ !14"..,#/<3". "-B H#631CC 36-4#6.V
Z6#> G6#31 4#"<-<-/ T!6B,.1 \[ 81C</- 6G @14"..<3 36@)6-1-4C "-B
Z6#> G6#31 4#"<-<-/ T !6B,.1 &[ !"3E<-1 36-4#6. "-B H#631CC
Z6#> G6#31 4#"<-<-/ T!6B,.1 9[ NE"#"341#<="A6- @14E6BCV
O20 H#631CC ;1-3E@"#><-/
8"4" 36..13A6- B,#<-/ ;,<.B$,)C G6# 5< 671#."*C
8"4" 36..13A6- B,#<-/ ;,<.B$,)C G6# 5< 671#."*C
H"]1#- #136/-<A6- "./6#<4E@ B171.6)@1-4
H#1B<3A71 @6B1. "-B G11B;"3> 36-4#6. B171.6)@1-4
H,;.<3"A6-
^,<B1.<-1 B63,@1-4
-v Maps, dlluuon & peneLrauon
8ulld-up for corroslon Lesung
Shape lab (Concave & Convex overlays)
-v Maps C/n plck-up & LhroughpuL
8ulld-ups - C1 & mech. props.
Shape lab. (L, L, and x walls)
Lducauon of Leam members
Work force Lralnlng
LCS roc. benchmarklng
auern rec. algorlLhm dev.
redlcuve model & feedback conLrol dev.
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Workforce and Lducanona| Cutreach Approach
1he educauon and workforce developmenL poruon of hls pro[ecL on Plgh 1hroughpuL
luncuonal MaLerlal ueposluon uslng a Laser PoL Wlre rocess" wlll be focused on Lhe
paruculars of meLal-focused addluve manufacLurlng raLher Lhan dupllcaLe Lhe broad
base of general AM or 3u educauon LhaL has been and conunues Lo be developed.
llve modules wlll be recorded and made avallable as weblnars, and on AM and
CW8u webslLes: a) lmporLance of Plgh 1hroughpuL, b) MeLallurglcal/
MlcrosLrucLural ConLrol, c) ueslgn of MeLalllc ComponenLs and uevlces, d)
Machlne ConLrol and rocess 8eproduclblllLy, e) CharacLerlzauon MeLhods.
Conunue presenLauons aL meeungs and weblnars for Lrade assoclauons (Lwo Lo
daLe) and aL companles (Lhree Lo daLe).
lncreased lnLegrauon wlLh ASM lnLernauonal MaLerlals Camps for PS 1eachers.
lnLegrauon lnLo Lhe Weldlng Lducauon sysLem of Lhe Llncoln LlecLrlc Company.
lnLroducLory graduaLe, upper-level undergraduaLe, course scheduled for fall 2014.
Course wlll be oered by dlsLance learnlng and permanenL recordlngs wlll be
made.

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Laser PoL Wlre oers hlgh-deposluon raLe (>10 lbs/hr),
process emclency, meLallurglcal conLrol, and lnLegrauon wlLh
lnLer-layer machlnlng.

1wo nonferrous alloys sysLems Lo be developed lnLended Lo:
asslsL Lhe exLenslon of AM Lo corroslon sensluve appllcauon
areas, e.g., oll & gas, and demonsLraLe AM as an alLernauve
Lo forglngs of lmporLanL llghLwelghL sLrucLural alloys.

Supply chaln represenLauon ls broad.

CuLcomes Lo lnclude demonsLraLed mlcrosLrucLure &
properues for Lwo alloy sysLems, and new AM machlnery.
Summary
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