Certification of Additive Manufactured Parts for Energy and Offshore

Copyright TWI Ltd and Lloyd's Register Group Services Ltd 2015Copyright TWI Ltd and Lloyd's Register Group Services Ltd 2015
Joint Industry Project Launch Event 29 September 2015
Certification of Laser Powder Additive Manufactured Components for Industrial Adoption
in the Energy and Offshore Sectors

What are we going to cover
Item Presenter
1 General introduction Luke Morsillo
2 TWI introduction Ian Norris
3 Lloyd’s Register Energy introduction Andy Imrie
4 Current state of the art in additive manufacturing Roger Fairclough
5 Presentation of the Project Outline proposal
Ian Norris, Amanda
Allison, David Hardacre
Short 5 minute coffee break and virtual slideshow
6
Discussion of technical content, timeliness, duration and
likely support of the proposal, including general Q&A
All
7 Any other business Luke Morsillo

Acronyms and abbreviations
We’ll use a number of different phrases
within this presentation
• AM/3DP/ALM: Additive Manufacturing
• NDE: Non-Destructive Examination
• NDT: Non-Destructive Testing
• LMD: Laser Metal Deposition
• SLM: Selective Laser Melting
• JIP: Joint Industry Project
• DOE: Diffractive Optical Elements

What’s the purpose of the launch event
Discuss the questions and
commentary on the technical
content, benefits and
deliverables of the project
• We encourage open
discussion on how relevant
the project’s aims are to your
organisation and the
industry.
Establish the timeliness of
the project
• We are looking to the
participants today to provide
a gauge of how mature AM
is within the industry.
Establish the likely support
for the project
• We’ll be following up 1:1 with
each of you in the next week
to discuss next steps.

Revolutionary technology does not automatically
result in saleable products overnight
• Barriers include legal, safety, reliability & repeatability.
• International standards and regulations are there to overcome these.
• ISO and ASTM standards are in development now but are years away from adoption.
These are the challenges that designers and manufacturers now face
Our project aims to forge a path to market, remove barriers, provide
expert guidance
And finally…the project
Copyright TWI Ltd and Lloyd's Register Group Services Ltd 2015

Project outline
The objectives of this project are to assist industry with the wider
adoption of AM technology by…
Identifying the priority measurement and standard compliance challenges of the Energy and
Offshore sectors.
Undertaking certification of a range of representative parts selected by the project sponsors.
Creating protocols that address the specific material and process needs of each sponsor.
Setting an example framework for certification and providing valuable information and data for
AM standard development across industries and research fields.
1
2
3
4

Benefits to sponsors
Certified parts that meet industrial requirements for quality, safety, and consistency, and
which are qualified ready for market introduction.
Improved knowledge of AM processes and practises to ensure repeatability and
reproducibility and facilitate the certification of future parts.
Decreased cost of certification by leveraging expert processing and certification knowledge
and experience from both TWI and LR Energy.
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TWI introduction
Dr Ian Norris, JIP Product Manager (TWI)

Mission
To provide authoritative and impartial expert
advice, knowhow and safety assurance
through engineering, materials and joining
technologies.

Over 700 Industrial members in
60 countries
Over 800 staff
£80M turnover
• Non profit distributing
Over 24,000 trainees/ year
Membership based Research
and Technology Organisation
Established 1946
TWI – serving our members

UK network
Port Talbot
Middlesbrough
Cambridge
Aberdeen
Rotherham
UK network

Worldwide network

TWI – technology engineering
• Research, Development, Technical support
and consultancy in all welding & joining
processes:
• Arc, EB, Laser, solid state, adhesive
etc.
• Innovative solutions to joining materials:
• Metals, plastics, ceramics, composites.
• Surface Engineering:
• Spraying, coating, surface
modification.
• Metallurgy & corrosion expertise.
• Structural Integrity.
• Failure analysis:
• Creep, fatigue & fracture testing.
• Design and manufacturing engineering.
• Training and certification.

Support for industry
• Helpdesk Technical support
• Duty.Engineer@twi.co.uk
• Over 15,000 visitors to TWI
technical centres
• Over 800 confidential, Single
Client Projects
• 20 Joint Industry Projects
• £4M Core Research
Programme
• 65 Collaborative Programmes

Knowledge transfer
• Website technical information
• Best practice guides
• Member reports
• Published papers
• More than 1,000 FAQs
• Knowledge summaries
• Weldasearch
• TWI and industry news
• Conference and events
• Social networking

Our team today
We help our clients to
Amanda Allison Amanda has a BEng(Hons) in Materials Engineering and is currently employed
as a Project Leader in the Laser Additive Manufacturing (LAM) section of TWI
Ltd. Her key responsibilities include: promoting advancements in Additive
Manufacturing technologies; preparing technology and innovation proposals and
managing UK and EC funded technology and innovation projects.
Ian Norris Ian is the Product Manager for Joint Industry and Single Client Projects at TWI.
He is a metallurgist with a background in laser, EB and friction processing for
applications in the power generation, marine, construction, aerospace and oil
and gas sectors. His current role involves working together with technical
experts on development of timely project proposals to address industry needs.
Roger
Fairclough
Roger is a Principal Project Leader in the Joining Technologies Group at TWI,
based at the Technology Centre in South Yorkshire and involved with a range of
technologies but particularly Additive Layer Manufacture using lasers. He has
over forty years experience within UK engineering industry, having worked in the
mining, power generation, R & D and steel manufacturing sectors.

Lloyd’s Register Energy introduction
Andy Imrie, Business Development Manager (LR)

Where we started
Our heritage is genuinely historic
• Formed in 1760 in Edward Lloyd’s coffee house to
examine and ‘classify’ merchant ships according to
their condition.
We have 250 years of global marine history.
• The world’s first ship classification society and this
remains our core activity today.
…and over 100 years serving other industries
across society from energy, rail, food safety to
power and manufacturing.

What we do
Improve safety and
reduce environmental
incidents or near
misses.
Ensure successful
delivery of major capital
projects and activities:
safely & on target.
Ensure the design and
manufacture of critical
equipment complies with
specifications and standards.
Extend asset life and
manage end of life.
Raise asset productivity,
efficiency and increase
uptime of critical
equipment.
Support adoption
of innovation and new
technology and extend
skills base.

Lloyd’s Register Energy at a glance
No1We are the no.1 provider
of verification services to
offshore operators in the
UK by market share.
80%
We inspect 80% of the
world’s offshore oil rigs. In
fact, we’re the leading
provider of independent risk
management services
to the drilling industry.
World leaders on codes
and standards
We are one of the largest providers of
ASME Authorised Inspection services by
market share in the world.
0 shareholders
We are financially and politically
independent and our services are
truly impartial.
We pioneered RBMI software
The industry’s first reliability-based
mechanical integrity (RBMI) software
which has radically advanced the
maintenance and management of
rotating and instrumentation
equipment.
90%
Fewer inspections points required by our
risk-based inspection management
software system, RBMI, compared to a
traditional programme. And the risk of
failures is reduced by 80-95%.
Up
to
100%
Owned by the Lloyd’s Register
Foundation, a UK charity dedicated to
research and education in science,
technology and engineering.

The sectors we support - Energy
We improve the safety, reliability and performance of assets, people, systems and processes across
the energy industry, helping our clients to solve the most demanding technical, regulatory and
commercial challenges.
Downstream
Upstream
PowerOil and Gas
Renewables Thermal Power
Nuclear Power

We provide assurance to manufacturers, vendors and operators that their equipment, materials and
components comply with statutory requirements, regulations and standards.
This reduces the potential risks to employees, the environment and our clients’ businesses and
reputations.
The sectors we support - Manufacturing
ComponentsMaterials Equipment

Experience at every manufacturing stage
• Global design
appraisal
capabilities.
• Processes to verify
and validate that
designs reflect
detailed
specifications.
• Capabilities to
validate all aspects
of material
properties.
• Extensive
experience with
EN standards,
including EN
10204:2004 Type
3.2 certification
and EN 1090.
• Witnessing of
NDE, heat
treatment, forging.
• Certification to
global codes and
standards.
• Ability to certify
weld procedures
and qualifications
to all major codes.
• Traceability of
components.
• Witness/
verification of
assembly
procedures.
• Snagging and
package
inspections.
• SUT, SIT, FAT
witnessing.
• Site receipt
testing.
• Manufacturing
record book
review.
• Issue certification.
Design Raw Materials Manufacturing Assembly Testing MRB

A world leader in certification to internationally recognised standards
One of the world leaders in certification of
businesses and products to internationally
recognised standards
• ASME, API, EC Directives/CE marking, IBR,
MHLW, MOM, NC-14 and DOSH.
LR also supports the development and evolution
of standards and codes through its involvement
in technical committees and working groups
• BSI, ASME, EU

Our core team is supported by our Global Technology Centres
We are operating with strong representation
from our two Global Technology Centres in
Singapore and Southampton
• Both centres work towards positioning LR
and our clients at the forefront of technology
to ensure that people are safe and that
essential assets perform as required.
• Our primary focus is on supporting
innovations for energy and shipping.
• We’ve grown a global research and
development network that spans across
academia, industry and government.
AM is one of the key technologies mapped
to our smart supply chain innovation
programme

Our team today
David Hardacre David is the Technical Lead on the Additive Manufacturing project for LR Energy.
He is a Chartered Mechanical Design Engineer with over seventeen years’
experience. He holds the role of Lead Specialist for LR Energy, performing
independent design calculations for a wide range of equipment to recognised
standards and regulations.
Andrew Imrie Andy works as part of the Energy Business Development Group responsible for
the upstream, downstream, power and manufacturing businesses. He is at the
forefront of identifying trends within the marketplace and maintains a strong
focus on facilitating and delivering collaborative innovation and technology
projects.
Luke Morsillo Luke is the project manager and analyst for all additive manufacturing projects
and activities within Lloyd’s Register Energy. Luke has several years
background in project and business management and analysis, with a strong
focus on information systems and technology.

Current state of the art in additive manufacturing
Roger Fairclough, Principal Project Leader (TWI)

TWI’s AM activities
Additive
Manufacturing
Repair
Surfacing
and Coating
Prototyping
Legacy
Parts
Small Batch
Production
Customised
Products
Salvage
Parts
OEM
R&D
Activities
Part
Production
Activities

Additive manufacturing technology
Powder bed deposition
Selective Laser Melting (SLM)
Nozzle powder delivery
Laser Metal Deposition (LMD)

Selective Laser Melting (SLM) capability
Micro SLM50 Realizer SLM100
Renishaw AM250 Rapid Part System 1kW

Design optimisation for additive manufacturing
Used to create designs that
exploit AM processes
Introduce complex
geometries
(sub-structures and lattices)
Multiple-part assemblies
combined into single builds

Topology optimisation
Courtesy of GE

Structural efficiency can be improved by enabling optimised topology that could not normally
be achieved by machining or casting.
A collaboration between the following organisations: TWI Ltd, University of Exeter, EADS UK,
Bombardier Aerospace plc, TISICS Ltd and Materialise UK. The Project was managed by TWI Ltd
and partly funded by the TSB under the Technology Programme ref: “AB183A”. TP No:
TP11/HVM/6/I/AB183A.
Selective Laser Melting (SLM) Topology

Traditional “Machining” process flow
AM process flow
Issue
Material
Turn
Gun
Drill
Thread
Drill
Sculpture
Mill
Proximal
Milling
Digital
Milling
Bend
and Bow
Glass
Bead
Anodise
QA QA QA QA QA QA QA
Post
Processing
Heat
Treatment
Finishing
AM Build
Build
Parameter
Machine
Powder
Supports
Design
Optimisation
QA?
AM and “traditional” approachesPartDesign
FinalInspection

TWI LMD hardware overview

Robotic LMD Capability Manipulation
New
TRUMPF
5.3/8kW
Disk
Laser
KUKA
KR30
(HA)
Robot
Cell
REIS
RV60-40
Robot
Cell

Oil and gas flange
• Standard flange
manufactured in SS316
and clad internally and
on the raised face with
Inconel 625 using In625
powder and laser
deposition.
• This is an alternative to
the manufacture of the
flange in solid Inconel
625, which significantly
reduces the materials
costs.
Standard flange in SS316 material
Flange laser deposited with In625 and
final machined to finished dimensions
Flange with laser deposited In625

Repair of hydraulic pump shafts
• Deposited like for like material of a
Ni-Cr-Mo Steel.
• Able to both maintain a tight control
on costs without compromising
quality.
• Reduce lead times for their repaired
units.

EC Project
Aims
• Deposition procedures for combustion chamber parts.
• Material IN718.
• Reduce time to manufacture
(2-3 months -> 6 hours).
Challenges
• Complex shape.
• Thin wall (0.8mm), Ra (15-25µm).
• Large aspect ratios i.e. thin wall (0.8mm) vs. overall build height
(~100mm) 300mm dia.

Lead time reduction

Lead time reduction
The MERLIN project has
received funding from the
European Union's Seventh
Framework Programme for
research, technological
development and demonstration
under grant agreement no
266271.

Inline LUT NDT Inspection

Diffractive Optical Elements (DOE)
Conventional LMD using
‘Gaussian’ Profile DOE based LMD (Theoretical optimal)
TSB/Innovate UK: SCAMPER

Beam profile

Integrated Manufacture

Concept for in-situ repair
IN-SIDE project:
• Automation of repair by machining and LMD tools
integration.
• Combination of 3D scanning with CAD/CAM
software.
• Automatic tool path generation of all repair tools.
• Development of an integrated mobile robotic LMD
system incorporating laser safety.
• Optimisation of LMD repair process:
• Reduce cracking in Stellite 6 deposits.
• Investigate alternative repair materials
(martensitic SS).
• Reduction of part distortion.

Repair of vintage aircraft landing gear
Crack indication under
NDT
Build internal sleeve LMD repair welding into
sleeve
Final repair after
machining bore

Turbine Shaft Cladding
• Over a period of 5 years we have worked with an industrial gas turbine
manufacturer to develop laser deposition processes for the cladding of
bearing journals on a range of industrial gas turbine shafts to combat
wear and corrosion.
• The shaft materials include Ni alloy and martensitic stainless steel and
the cladding material is a NiCrMo high tensile steel.
• There are strict limits for defects (porosity, cracks) and min hardness
levels and max Cr levels to achieve.
• Heat input is restricted to reduce dilution and hence Cr content in the
deposit.
• TWI has produced Weld Procedure Specifications for the different
materials and developed process control systems to ensure deposition
quality and consistency.
• The work is being carried out using our Trumpf laser deposition system
and integrated rotator

LMD vs conventional processing
• Alternative conventional processes:
• Metal Spraying
• Arc welding – MMA, MIG, TIG, Plasma Transfer Arc
• Ability to achieve technical specification:
• Surface chrome content
• Surface and interface hardness levels
• Full traceable record of deposition- parameters/heat input etc.
• Benefits include:
• Full fusion/high bond strength to substrate
• Low heat input, low dilution, low distortion
• Small HAZ
• Least effect on substrate
• Good surface finish
• High accuracy
• High repeatability

Presentation of the Project Outline proposal
Amanda Allison, Principal Project Leader (TWI)
Dr Ian Norris, JIP Product Manager (TWI)
David Hardacre, Technical Leader (LR)

What is a joint industry project
• Opportunity to develop cutting edge
technology supported by industry.
• Topic of mutual interest to a number of
clients.
• Issues relating to safety and integrity.
• Development of codes and standards.
• Generic process development.
• Generation of materials properties data.
• Results confidential to Sponsor Group.

The proposal process
Launch Meeting
• Presentation of outline
proposal.
• Establish the timeliness of
the proposed project.
• Obtain input on the technical
content, deliverables and
benefits.
• Establish the likely support
for the project.
Launch Follow Up
• Prepare and issue full
proposal.
• Participation Agreements
(PAs) to potential sponsors.
• Individual discussions as
required.
Project Start
• When agreed number of
Sponsors have returned
PAs.
• Kick-off meeting.
• Agree work plan for first 6
months.

Project organisation
Sponsor meetings
• 6 month intervals.
• Report results to date and review progress.
• Plan work for following period.
• Final meeting.
• Overview of project results.
• Implementation and future plans.
Reports
• Bi-monthly progress updates.
• 6 monthly ahead of meetings or deliverables based.
• Final report drawing together all results.
• Reporting is done via a secure project website.

Revolutionary technology does not automatically
result in saleable products overnight
• Barriers include legal, safety, reliability & repeatability.
• International standards and regulations are there to overcome these.
• ISO and ASTM standards are in development now and will tackle a number of the challenges
facing the AM community:
• CAD model translation.
• Powder size and quality.
• Recyclability of powder.
• Variability between AM machine models.
• Support structures.
• Build parameters.
These are the challenges that designers and manufacturers now face
Background

We created this joint industry project to…
Forge a path to market
Remove barriers
Provide expert guidance

The case study technologies
Powder bed deposition
Selective Laser Melting (SLM)
Nozzle powder delivery
Laser Metal Deposition (LMD)

Our approach

Discussion and Q&A

Any other business

Next steps

Our timeline
Contracts Kick-off and project delivery
Oct-
15
Nov-
15
Dec-
15
Jan-
16
Feb-
16
Mar-
16
Apr-
16
May-
16
Jun-
16
Jul-
16
Aug-
16
Sep-
16
Oct-
16
Nov-
16
Dec-
16
>>
2017
Follow up
1:1 by our
team Discussions on project scope
Finalisation
of Project
Outline
w/e 04-Oct w/e 11-Oct w/e 18-Oct w/e 25-Oct w/e 01-Nov w/e 08-Nov

Get in touch
JIP Co-ordinator
Luke Morsillo
Email: luke.morsillo@lr.org
Technical Lead
David Hardacre
Email: david.hardacre@lr.org
JIP Co-ordinator
Kirsty Jones
Email: jip@twi.co.uk
Technical Lead
Amanda Allison
Email: amanda.allison@twi.co.uk
Find out more at: www.lr.org/additive-manufacturing
Find out more at: http://www.twi-global.com/services/research-and-
consultancy/joint-industry-projects/

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