Fl ui d Power

Appl i c at i ons f or
Emer gi ng Tr ends i n
Addi t i ve Manuf ac t ur i ng
Lonnie Love
Manufacturing Systems Research
Manufacturing Demonstration Facility

Oak Ridge National Laboratory
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Out l i ne
Background
ORNLs push in manufacturing
Bringing $B of scientific tools to manufacturing
Focus on Additive Manufacturing and Carbon Fiber
Impact on Efficiency
Weight reduction
Mesoscale valves
Zero tare flow, digital and thermal poppets
Creative designs blending additive/carbon fiber and fluid power
Role in workforce development
Using AM to drive kids to STEM
Partnering with America Makes (NAMII) and FIRST
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DOEs f i r st Manuf ac t ur i ng Demonst r at i on Fac i l i t y at Oak Ridge National Laboratory
A DOE-funded facility promoting broad and rapid dissemination
of advanced manufacturing technologies
ORNLs Car bon Fi ber Tec hnol ogy Fac i l i t y
A DOE-funded facility for demonstrating advanced
technology scalability and producing market-development
volumes of prototypical carbon fiber
Production capacity:
25 tons/yr fiber from multiple
precursors in various forms
Additive Manufacturing enabling
product customization, improved
performance, multifunctionality and
lower overall manufacturing costs
Carbon Fiber and Composites enabling
widespread deployment in high-volume,
cost-sensitive energy applications
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Addi t i ve Manuf ac t ur i ng (AM)
Additive Manufacturing will
become the most important,
most strategic, and most used
manufacturing technology ever.
Wohlers 2012
Increased Complexity
Less Material Scrap
Shorter Design Cycle
Reduced Part Count
Faster
Cheaper
Better!
CAD Model to Physical Part
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Addi t i ve Manuf ac t ur i ng (AM)
MDF Thr ust Ar ea
Leveraging key resources at ORNL to accelerate
technology implementation
Developing advanced materials
Titanium alloys, Ni superalloys, stainless and ultra high-
steels
High-strength, carbon-reinforced polymers
Implementing advanced controls
In-situ feedback and control for rapid certification and
quality control
Understanding material properties and geometric
accuracy
Exploring next-generation systems to overcome
technology barriers for manufacturing
Bigger, Faster, Cheaper
Integrating materials, equipment and component suppliers
with end users to develop and evolve the supply chain
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Developing in-situ
characterization, feedback
and control
Precision melting
of powder materials
Processing of complex
geometries not possible
through machining
Electron
Beam Melting (4)
Simultaneous additive
and subtractive
process
for manufacturing
complex geometries
Solid-state process
allows embedding
of optical fibers
and sensors
Ultrasonic Additive
Manufacturing (1)
Site-specific
material addition
Application of advanced
coating materials
for corrosion
and wear resistance
Repair of dies, punches,
turbines, etc.
Laser Metal
Deposition (1)
High Resolution
Unsintered support
powder (easy removal)
Wide variety of materials
Laser Powder Bed
(1)
High deposition rate
Large volume
Metal, polymer and
ceramic feedstock
Laser Sintering (2)
9 Metal
Working with AM equipment providers to develop high-performance materials, low-cost feedstocks, processing
techniques and in-situ characterization and controls to enable broad dissemination of technologies
Current Equipment
Addi t i ve Manuf ac t ur i ng (AM)
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Developing in-situ
characterization,
feedback and control
New high strength
materials
Increased z-strength
Fused Deposition Modeling (4)
Multi-materials
Very high resolution
Stereolithography(1)
Enormous growth
Low-cost (<$2K)
Open source so easy
for new material and
control development
Desktops (15)
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Current Equipment
Addi t i ve Manuf ac t ur i ng (AM)
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Lever agi ng Bi l l i ons of Dol l ar s of R& D
Sc i enc e t o Appl i c at i on
Cr i t i c al t o w i despr ead adopt i on of t ec hnol ogy
Profilometry map illustrating distortion
Advanced materials and processing to expand
available materials
Sensing and controls to provide reliability
Neutron science and advanced microscopy to
understand material properties
High performance computing to build models
to enable future design and processing tools

Laser AM creates
large residual
stress leading to
distortion
laser AM of turbine blade
Understanding link between residual
stress and additive manufacturing
Utilizing neutron science to impact industry
turbine blade
Reconstructed image using
neutron tomography
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E-beam appr oac h: Hydr aul i c hand
Additive processes enable integrated pump, fluid passages and pistons into a
structure with mesh for weight reduction
Titanium hand made using E-beam fusion (operating pressure 3000 psi)
Curved fluid
passages
Pistons integrated
into structure
Integrated
motor and
pump
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Mec hani c al c onsi der at i ons
Mechanical Strength
Hold to well over 6000 psi at 0.020 wall thickness on 0.125 tube




Wrought Mechanical properties, even for 0.015 AM mesh



Polish internal cavities
No finishing Aggressive finishing
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Mesh st r uc t ur es f or wei ght r educ t i on
Blending hydraulics and AM






Less mass means
Less material
Less energy
Faster build
Lower cost
Solid palm weighing 857 grams.
Meshed palm weighing 178 grams
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Of f i c e of Naval Resear ch: Under wat er r obot i c s
Completely printed arm
Target is neutrally buoyant without any floatation devices
Shell structures for weight reduction (0.030 wall thicknesses)
Total weight of 60 long arm is 25 lbs.
Integrated hydraulics and electronics (nothing penetrates the skin)
No hoses, fluid passages integrated into structure
Anthropomorphic design
7 Degrees of freedom
Antagonistic actuation at each joint
Each joint has 180 degrees of rotation
Custom thermal valves for energy efficiency
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ONR under wat er r obot i c s
Involute cam joint
Barrel cam joint
Design rule: Provide 0.030 to 0.050
excess material on bearing surfaces
and piston bores.
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Mesosc al e val ves
High pressure (>3000 psi), low flow (<10 mL/min) control valves
Three designs all based on poppet valves
Direct flow control via liquid cooled SMA
Zero tare flow
Independent chamber control (regeneration)
Low bandwidth (< 10 Hz), but low-cost fabrication/assembly
Very mature (have manufactured hundreds, implemented on underwater robot)
Digital flow control
Zero tare flow
High bandwidth (> 200 Hz)
Still needs maturation
Two stage digital valve
High flow rate via two stage poppet
Digital valve modulates pressure in large poppet
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Car bon Fi ber FDM Composi t es
CF-ABS
2x strength
4x stiffness
ABS
CF-ABS
Compounded filament printed on Solidoodle 3
10-15% CF by weight
Dramatically reduced curl
Lindahl ACCE (2013)
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Collaboration between ORNL, Lockheed Martin
and Equipment Manufacturer
Materials low CTE, high strength materials
Deposition new methods of deposition and
control
Multiple-robot coordination (8 x 8 x 8 gantry,
Kuka Robot)
Pellet-to-Part: Enables manufacturing of large
components using pelletized feed.
Bi g Ar ea Addi t i ve Manuf ac t ur i ng (BAAM)
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Bi g Ar ea Addi t i ve Manuf ac t ur i ng (BAAM)
Large scale deposition system
Unbounded build envelope
High deposition rates (~20 lbs/h)
Direct build components
Tools, dies, molds
Carbon fiber material reduces
warping out of oven
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Out -of -oven
Manufacturing carbon fiber reinforced
materials
Shows increased strength and significant
reduction in distortion
Preliminary testing on in-situ post-processing
was successful
Making sample parts for NavAir Cherry Point.
Exploring new materials
CF ABS, CF Ultem, PEKK
For surface finish, have integrated fly cutter
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FIRST Robotics Competition 20112012 teams now at work
Founded by Dean Kamen
(Segway inventor):
For Inspiration and
Recognition of Science
and Technology
Goal: Inspiring youth
to be science and
technology leaders
Opened ORNL MDF to work with 8
area high schools
Over 50 mentors and teachers
Over 200 students
Over $200K in industrial
support (Stratasys, DOE AMO,
NFPA, Bimba )
All schools learn to use AM
2012 Smoky Mountains Regional
Competition
Hardin Valley Academy
Engineering Excellence Award
(first completely AM Robot!)
Oak Ridge High School
Top Rookie All Star Award &
Nationals Contender
Webb High School
Woodie Flowers Finalist Award
Knoxville Catholic High School
and Seymour High School
Ranked in the Top 5


The f ut ur e of manuf ac t ur i ng?
STEM - Hi gh School Robot i c s Teams
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ORNL, FI RST and HVA
Using FIRST as a platform to teach next generation of engineers about
manufacturing
Shown to over 200 companies, 1000 visitors
Students took to NAMII kickoff and DMC
Five students designed system
Shooter signed by policy makers
This is the highlight
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Hybr i d Assembl i es
First Robotics Team #3824
Hardin Valley Academy
RoHawktics
Sponsored by ORNL Manufacturing Demonstration Facility
(MDF)
Hybrid Assembly
FDM Fittings
Pultruded Rods
Filament winding
Benefits
Additive is great at relatively smaller more complex
Carbon fiber is great at long, simple, light weight, high
strength structures
Combining provides strengths of both technologies
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Fi r st Robot i c Team #3824
Application
Robot Chassis
Stiff/light weight
Solution
FDM light weight end pieces with critical
interfaces
Pultruded carbon rods for spanners
Filament wound for bonding and
strength/stiffness
Results

22
Part Length
AM Only Hybrid
Fab Time Weight Fab Time Weight
Long Beam 54 90 hrs 14.64 lbs 15.5 hrs 3.86 lbs
Short Beam 21 24 hrs 7.44 lbs 8.25 hrs 1.77 lbs
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Team #3824, supported by DOEs MDF,
wins award for most 3D printed parts on
robot, ranks #10 in division
Sc i enc e, Technol ogy, Engi neer i ng & Mat hemat i c s (STEM)
DOEs MDF Par t ner s w i t h NAMI I t o
Showc ase Addi t i ve Manuf ac t ur i ng at
2013 FI RST Champi onshi p i n St . Loui s
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Concl usi on
Many opportunities for fluid power industry in advanced
manufacturing
Additive for:
Weight reduction
Integration of hydraulics with structure
Existing program with Aerovalve (Ellen Mell)
New carbon fiber reinforced polymers for wider spectrum of
applications
Low cost carbon fiber
Target $5/lb
Integration with feedstock or development of hybrid systems
Importance of STEM
ORNL and NAMII partnering with FIRST
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Di sc ussi on
Lonnie Love
lovelj@ornl.gov
(865) 576-4630