Inspiring Day "Industria y Fábrica del Futuro" (Fernando Lasagni - Catec)
20
Oportunidades y retos de la Fabricación Aditiva y la Automatización de Procesos en el sector Aeroespacial Juan Pedro Vela General Manager Carlos Pérez Head of Automation & Robotics Prospects and Challenges of Additive Manufacturing and Process Automation in the Aerospace Industry Andalusian Foundation for Aerospace Development (FADA) Center for Advanced Aerospace Technologies (CATEC) Fernando A. Lasagni Head of Materials & Processes
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Inspiring Day es un foro de encuentro donde visualizar escenarios futuros, desarrollar negocio o identificar nuevas oportunidades de diversificación, a través de la investigación y el desarrollo tecnológico. Este evento tuvo lugar en Sevilla, en Parque Aerópolis, el 12 de diciembre de 2013. Más información en http://www.tecnalia.com/inspiringday/
Transcript of Inspiring Day "Industria y Fábrica del Futuro" (Fernando Lasagni - Catec)
Oportunidades y retos de la Fabricacioacuten Aditiva y la
Automatizacioacuten de Procesos en el sector Aeroespacial
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Fernando A Lasagni Head of Materials amp Processes
Application examples
Motivation
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Additive Manufacturing
RTM
Infusion tech
metals
composites
Some of the Major issues within
aircraft industry
Augmented reality Virtual reality
ALM requires of advanced NDT
3D CFRP parts
Decrease inspection time
Software tools and novel
inspection strategies
Structural Health Monitoring
Manufacturing
- Near net shape processing
- Out off autoclave curing (composites)
Assembly
- Simulation tools
Inspection
- Versatile full field NDT methods for
complex geometries
- Automation
- Automatic detection and evaluation
- Continuous Monitoring (maintenance)
Summary of presentation
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Metallic Manufacturing
- Today amp Next Generation (ALM)
- Materials and Post Treatments
- Advanced inspection methods
- Application case Project ALM
Polymer base Composites fabrication
- Automation of NDT
- Dimensional analysis
- Structural Health Monitoring
Metallic Manufacturing today
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Shaping into Components
Forging
Ring Rolling
Metal Removal (Machining)
Near Net Shape Processes
Casting
Powder Metallurgy
Conventional Sheet Forming
Superplastic Forming and Diffusion Bonding
Constraints in shape Additive Layer Manufacturing
Design driven technology
Manufacturing
technology driven
design
Additive Layer Manufacturing - Fundamentals
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Near Net shape manufacturing
3D complex geometries
Topological optimization
(same functions with optimized weight)
Available commercial aerospace materials
Lower product development costs
Green technology
Stainless Steel AISI316L
Antennas IF Brackets
CASA-ESPACIO
CATEC
ALM ndash Topology Optimization
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
ALM Perfect application for topology optimization Topology
optimization has to be lsquointerpretedrsquo and sacrifices in the design
have to be made for conventional manufacturability
Source copy Altair Engineering EADS Innovation Works Topology Optimization of an Additive Layer Manufactured (ALM) Aerospace Part
A320 nacelle hinge bracket
FEA of original part at
max stress cases
FEA of optimized
ALM part
gt60 weight
reduction
Materials
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Commercial Available Metallic Materials (eg Renishaw)
EADS Innovation Works ScalmalloyregRP (AlMgSc) 6061 Morris
Future developments
- Aerospace alloys
- Metal Matrix Composites (eg particle reinforcements)
- Nano Reinforced Materials (Metallic and Polymer base materials)
Ultimate Tensile [MPa]
SLM ldquoconventionalrdquo
ST 900-955degC
Aged 540degC
1130 1170
Stress Relief
1200degF 3 hours
vacuum
Post treatments
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Parts manufactured by ALM presents accumulated internal stresses due to
fast solidification of the melt during fabrication (also influence by shape part
laser scanning strategy etc)
Part roughness must by adjusted to application req (as manufactured = 10-20 Ra)
eg heat treatments
Electrochemical processes
Laser assisted (eg laser beam
machining)
Grindingpolishing
Fatigue life improvement and roughness improvement
Shot Peening
Laser Peening
Electron Beam hardening
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
NDT inspections 100 full volume
copy GKN Aerospace
Optimized A380
bracket copy EADS
Innovation Works
Optimized A320 bracket
copy EADS Innovation Works
CFRP Load Introduction Rib
copy Airbone Aerospace
Advanced NDI methods
Available during product
development stages
ALM inner porosity
dimensional distortion
(internal stresses) etc
must be analyzed
CFRP fixtures eg radii
inspections requires of
complex and time
consuming UT inspections
Computed Tomography
reliable method for product
development and complex
inspections
2D Cross-sections
X-Ray Tube
Rotating stage
Detector
Specimen
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography
Inner features
3D-Reconstruction
Object surface
Materials characterization
NDT
Metrology
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography ndash Application examples
Actual to Nominal Comparison Inner features
Variance distribution
ALM part for
clampband ARIANE5
3D Characterization
Porosity ~5 ~2 lt05
CASA-ESPACIOCATEC 3D View
Cross
section
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Application Example
FLPP Systems 22
Additive Layer Manufacturing ndash ALM
FLPPCTMampSALM (ITT AQ1-7103)
Evaluation of the potential benefits (and drawbacks) of a designed
combination of ALM technology materials and applications for future
launchers and next generation of space hardware
Design of more efficient parts (aprox 19000euroKg)
ldquoDecrease manufacturing costsrdquo
Design leading technology (ALM)
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Identification of potential target
applications in Launcher Vehicles and ALM
Technology assessment
ARIANE 5 Launcher Structural Stages with EADS CASA-
ESPACIO participation
ALM Project Logic
Phase 1 (finished)
Screening for target application
Phase 2 (finished)
Mechanical characterization and
advanced NDT
Definition of development
and verification plan
Phase 3 (in progress)
Execution of technology
development and verification
plan
Preliminary Breadboard
definition and topological
optimization
Phase 4 (in progress) Phase 5 (not started)
Manufacturing
amp Verification
Composites - Manufacturing today
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
(1) Innovative processing Advanced Manufacturing
(2) Adaptive and smart manufacturing systems
(3) Digital virtual and resource-efficient factories
(4) Collaborative and mobile enterprises (5) Human centric manufacturing and (6) Costumer focused mnf
Research and innovation priorities (H2020)
Raw Material Pre-preg
Vacuum Bag Autoclave
Curing
Out Of Autoclave
Repairs + Automation
SHM
Finishing
NDT + automation
NDT + automation
NDT + automation
Joining and Assembly
Repairs + Automation
SHM
New possibilities
Automation
Automated inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Source TECNATOM SA
Source TECNATOM SA
Multi Robot inspection (ultrasonics)
Non-contact Laser UT
Target Increase flexibility
- Automated flexible process - Object and NDT system manipultation
- Non-contact inspections - Data acquisition and processing
- Quantitative analysis and evaluation
Dimensional analysis
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Contactless 3D reconstruction
Path optimization
Control
Positioning
Acquisition
Location
CCD cameras
Interior Inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Reduced work space
Detection of indications objects and
leakages
Source OC Robotics
(wwwocroboticscom)
Project
subcontractor
Composites - Monitoring
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Structural Health monitoring of
aerostructures during
In service
bonded embedded
Application example FBG Real time signal Data processing strategies
Scheduled maintenance
Manufacturing
Composites ndash Aging
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Effect of environmental factors on composite life
eg temperature humidity oxygen 500 cycles oxidative 30 cycles inert
300 cycles
inert+
ldquoTrdquo CFRP profile
Temperature +
Vibration + load
Sample level
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
Application examples
Motivation
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Additive Manufacturing
RTM
Infusion tech
metals
composites
Some of the Major issues within
aircraft industry
Augmented reality Virtual reality
ALM requires of advanced NDT
3D CFRP parts
Decrease inspection time
Software tools and novel
inspection strategies
Structural Health Monitoring
Manufacturing
- Near net shape processing
- Out off autoclave curing (composites)
Assembly
- Simulation tools
Inspection
- Versatile full field NDT methods for
complex geometries
- Automation
- Automatic detection and evaluation
- Continuous Monitoring (maintenance)
Summary of presentation
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Metallic Manufacturing
- Today amp Next Generation (ALM)
- Materials and Post Treatments
- Advanced inspection methods
- Application case Project ALM
Polymer base Composites fabrication
- Automation of NDT
- Dimensional analysis
- Structural Health Monitoring
Metallic Manufacturing today
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Shaping into Components
Forging
Ring Rolling
Metal Removal (Machining)
Near Net Shape Processes
Casting
Powder Metallurgy
Conventional Sheet Forming
Superplastic Forming and Diffusion Bonding
Constraints in shape Additive Layer Manufacturing
Design driven technology
Manufacturing
technology driven
design
Additive Layer Manufacturing - Fundamentals
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Near Net shape manufacturing
3D complex geometries
Topological optimization
(same functions with optimized weight)
Available commercial aerospace materials
Lower product development costs
Green technology
Stainless Steel AISI316L
Antennas IF Brackets
CASA-ESPACIO
CATEC
ALM ndash Topology Optimization
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
ALM Perfect application for topology optimization Topology
optimization has to be lsquointerpretedrsquo and sacrifices in the design
have to be made for conventional manufacturability
Source copy Altair Engineering EADS Innovation Works Topology Optimization of an Additive Layer Manufactured (ALM) Aerospace Part
A320 nacelle hinge bracket
FEA of original part at
max stress cases
FEA of optimized
ALM part
gt60 weight
reduction
Materials
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Commercial Available Metallic Materials (eg Renishaw)
EADS Innovation Works ScalmalloyregRP (AlMgSc) 6061 Morris
Future developments
- Aerospace alloys
- Metal Matrix Composites (eg particle reinforcements)
- Nano Reinforced Materials (Metallic and Polymer base materials)
Ultimate Tensile [MPa]
SLM ldquoconventionalrdquo
ST 900-955degC
Aged 540degC
1130 1170
Stress Relief
1200degF 3 hours
vacuum
Post treatments
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Parts manufactured by ALM presents accumulated internal stresses due to
fast solidification of the melt during fabrication (also influence by shape part
laser scanning strategy etc)
Part roughness must by adjusted to application req (as manufactured = 10-20 Ra)
eg heat treatments
Electrochemical processes
Laser assisted (eg laser beam
machining)
Grindingpolishing
Fatigue life improvement and roughness improvement
Shot Peening
Laser Peening
Electron Beam hardening
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
NDT inspections 100 full volume
copy GKN Aerospace
Optimized A380
bracket copy EADS
Innovation Works
Optimized A320 bracket
copy EADS Innovation Works
CFRP Load Introduction Rib
copy Airbone Aerospace
Advanced NDI methods
Available during product
development stages
ALM inner porosity
dimensional distortion
(internal stresses) etc
must be analyzed
CFRP fixtures eg radii
inspections requires of
complex and time
consuming UT inspections
Computed Tomography
reliable method for product
development and complex
inspections
2D Cross-sections
X-Ray Tube
Rotating stage
Detector
Specimen
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography
Inner features
3D-Reconstruction
Object surface
Materials characterization
NDT
Metrology
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography ndash Application examples
Actual to Nominal Comparison Inner features
Variance distribution
ALM part for
clampband ARIANE5
3D Characterization
Porosity ~5 ~2 lt05
CASA-ESPACIOCATEC 3D View
Cross
section
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Application Example
FLPP Systems 22
Additive Layer Manufacturing ndash ALM
FLPPCTMampSALM (ITT AQ1-7103)
Evaluation of the potential benefits (and drawbacks) of a designed
combination of ALM technology materials and applications for future
launchers and next generation of space hardware
Design of more efficient parts (aprox 19000euroKg)
ldquoDecrease manufacturing costsrdquo
Design leading technology (ALM)
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Identification of potential target
applications in Launcher Vehicles and ALM
Technology assessment
ARIANE 5 Launcher Structural Stages with EADS CASA-
ESPACIO participation
ALM Project Logic
Phase 1 (finished)
Screening for target application
Phase 2 (finished)
Mechanical characterization and
advanced NDT
Definition of development
and verification plan
Phase 3 (in progress)
Execution of technology
development and verification
plan
Preliminary Breadboard
definition and topological
optimization
Phase 4 (in progress) Phase 5 (not started)
Manufacturing
amp Verification
Composites - Manufacturing today
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
(1) Innovative processing Advanced Manufacturing
(2) Adaptive and smart manufacturing systems
(3) Digital virtual and resource-efficient factories
(4) Collaborative and mobile enterprises (5) Human centric manufacturing and (6) Costumer focused mnf
Research and innovation priorities (H2020)
Raw Material Pre-preg
Vacuum Bag Autoclave
Curing
Out Of Autoclave
Repairs + Automation
SHM
Finishing
NDT + automation
NDT + automation
NDT + automation
Joining and Assembly
Repairs + Automation
SHM
New possibilities
Automation
Automated inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Source TECNATOM SA
Source TECNATOM SA
Multi Robot inspection (ultrasonics)
Non-contact Laser UT
Target Increase flexibility
- Automated flexible process - Object and NDT system manipultation
- Non-contact inspections - Data acquisition and processing
- Quantitative analysis and evaluation
Dimensional analysis
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Contactless 3D reconstruction
Path optimization
Control
Positioning
Acquisition
Location
CCD cameras
Interior Inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Reduced work space
Detection of indications objects and
leakages
Source OC Robotics
(wwwocroboticscom)
Project
subcontractor
Composites - Monitoring
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Structural Health monitoring of
aerostructures during
In service
bonded embedded
Application example FBG Real time signal Data processing strategies
Scheduled maintenance
Manufacturing
Composites ndash Aging
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Effect of environmental factors on composite life
eg temperature humidity oxygen 500 cycles oxidative 30 cycles inert
300 cycles
inert+
ldquoTrdquo CFRP profile
Temperature +
Vibration + load
Sample level
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
Summary of presentation
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Metallic Manufacturing
- Today amp Next Generation (ALM)
- Materials and Post Treatments
- Advanced inspection methods
- Application case Project ALM
Polymer base Composites fabrication
- Automation of NDT
- Dimensional analysis
- Structural Health Monitoring
Metallic Manufacturing today
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Shaping into Components
Forging
Ring Rolling
Metal Removal (Machining)
Near Net Shape Processes
Casting
Powder Metallurgy
Conventional Sheet Forming
Superplastic Forming and Diffusion Bonding
Constraints in shape Additive Layer Manufacturing
Design driven technology
Manufacturing
technology driven
design
Additive Layer Manufacturing - Fundamentals
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Near Net shape manufacturing
3D complex geometries
Topological optimization
(same functions with optimized weight)
Available commercial aerospace materials
Lower product development costs
Green technology
Stainless Steel AISI316L
Antennas IF Brackets
CASA-ESPACIO
CATEC
ALM ndash Topology Optimization
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
ALM Perfect application for topology optimization Topology
optimization has to be lsquointerpretedrsquo and sacrifices in the design
have to be made for conventional manufacturability
Source copy Altair Engineering EADS Innovation Works Topology Optimization of an Additive Layer Manufactured (ALM) Aerospace Part
A320 nacelle hinge bracket
FEA of original part at
max stress cases
FEA of optimized
ALM part
gt60 weight
reduction
Materials
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Commercial Available Metallic Materials (eg Renishaw)
EADS Innovation Works ScalmalloyregRP (AlMgSc) 6061 Morris
Future developments
- Aerospace alloys
- Metal Matrix Composites (eg particle reinforcements)
- Nano Reinforced Materials (Metallic and Polymer base materials)
Ultimate Tensile [MPa]
SLM ldquoconventionalrdquo
ST 900-955degC
Aged 540degC
1130 1170
Stress Relief
1200degF 3 hours
vacuum
Post treatments
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Parts manufactured by ALM presents accumulated internal stresses due to
fast solidification of the melt during fabrication (also influence by shape part
laser scanning strategy etc)
Part roughness must by adjusted to application req (as manufactured = 10-20 Ra)
eg heat treatments
Electrochemical processes
Laser assisted (eg laser beam
machining)
Grindingpolishing
Fatigue life improvement and roughness improvement
Shot Peening
Laser Peening
Electron Beam hardening
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
NDT inspections 100 full volume
copy GKN Aerospace
Optimized A380
bracket copy EADS
Innovation Works
Optimized A320 bracket
copy EADS Innovation Works
CFRP Load Introduction Rib
copy Airbone Aerospace
Advanced NDI methods
Available during product
development stages
ALM inner porosity
dimensional distortion
(internal stresses) etc
must be analyzed
CFRP fixtures eg radii
inspections requires of
complex and time
consuming UT inspections
Computed Tomography
reliable method for product
development and complex
inspections
2D Cross-sections
X-Ray Tube
Rotating stage
Detector
Specimen
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography
Inner features
3D-Reconstruction
Object surface
Materials characterization
NDT
Metrology
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography ndash Application examples
Actual to Nominal Comparison Inner features
Variance distribution
ALM part for
clampband ARIANE5
3D Characterization
Porosity ~5 ~2 lt05
CASA-ESPACIOCATEC 3D View
Cross
section
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Application Example
FLPP Systems 22
Additive Layer Manufacturing ndash ALM
FLPPCTMampSALM (ITT AQ1-7103)
Evaluation of the potential benefits (and drawbacks) of a designed
combination of ALM technology materials and applications for future
launchers and next generation of space hardware
Design of more efficient parts (aprox 19000euroKg)
ldquoDecrease manufacturing costsrdquo
Design leading technology (ALM)
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Identification of potential target
applications in Launcher Vehicles and ALM
Technology assessment
ARIANE 5 Launcher Structural Stages with EADS CASA-
ESPACIO participation
ALM Project Logic
Phase 1 (finished)
Screening for target application
Phase 2 (finished)
Mechanical characterization and
advanced NDT
Definition of development
and verification plan
Phase 3 (in progress)
Execution of technology
development and verification
plan
Preliminary Breadboard
definition and topological
optimization
Phase 4 (in progress) Phase 5 (not started)
Manufacturing
amp Verification
Composites - Manufacturing today
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
(1) Innovative processing Advanced Manufacturing
(2) Adaptive and smart manufacturing systems
(3) Digital virtual and resource-efficient factories
(4) Collaborative and mobile enterprises (5) Human centric manufacturing and (6) Costumer focused mnf
Research and innovation priorities (H2020)
Raw Material Pre-preg
Vacuum Bag Autoclave
Curing
Out Of Autoclave
Repairs + Automation
SHM
Finishing
NDT + automation
NDT + automation
NDT + automation
Joining and Assembly
Repairs + Automation
SHM
New possibilities
Automation
Automated inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Source TECNATOM SA
Source TECNATOM SA
Multi Robot inspection (ultrasonics)
Non-contact Laser UT
Target Increase flexibility
- Automated flexible process - Object and NDT system manipultation
- Non-contact inspections - Data acquisition and processing
- Quantitative analysis and evaluation
Dimensional analysis
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Contactless 3D reconstruction
Path optimization
Control
Positioning
Acquisition
Location
CCD cameras
Interior Inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Reduced work space
Detection of indications objects and
leakages
Source OC Robotics
(wwwocroboticscom)
Project
subcontractor
Composites - Monitoring
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Structural Health monitoring of
aerostructures during
In service
bonded embedded
Application example FBG Real time signal Data processing strategies
Scheduled maintenance
Manufacturing
Composites ndash Aging
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Effect of environmental factors on composite life
eg temperature humidity oxygen 500 cycles oxidative 30 cycles inert
300 cycles
inert+
ldquoTrdquo CFRP profile
Temperature +
Vibration + load
Sample level
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
Metallic Manufacturing today
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Shaping into Components
Forging
Ring Rolling
Metal Removal (Machining)
Near Net Shape Processes
Casting
Powder Metallurgy
Conventional Sheet Forming
Superplastic Forming and Diffusion Bonding
Constraints in shape Additive Layer Manufacturing
Design driven technology
Manufacturing
technology driven
design
Additive Layer Manufacturing - Fundamentals
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Near Net shape manufacturing
3D complex geometries
Topological optimization
(same functions with optimized weight)
Available commercial aerospace materials
Lower product development costs
Green technology
Stainless Steel AISI316L
Antennas IF Brackets
CASA-ESPACIO
CATEC
ALM ndash Topology Optimization
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
ALM Perfect application for topology optimization Topology
optimization has to be lsquointerpretedrsquo and sacrifices in the design
have to be made for conventional manufacturability
Source copy Altair Engineering EADS Innovation Works Topology Optimization of an Additive Layer Manufactured (ALM) Aerospace Part
A320 nacelle hinge bracket
FEA of original part at
max stress cases
FEA of optimized
ALM part
gt60 weight
reduction
Materials
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Commercial Available Metallic Materials (eg Renishaw)
EADS Innovation Works ScalmalloyregRP (AlMgSc) 6061 Morris
Future developments
- Aerospace alloys
- Metal Matrix Composites (eg particle reinforcements)
- Nano Reinforced Materials (Metallic and Polymer base materials)
Ultimate Tensile [MPa]
SLM ldquoconventionalrdquo
ST 900-955degC
Aged 540degC
1130 1170
Stress Relief
1200degF 3 hours
vacuum
Post treatments
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Parts manufactured by ALM presents accumulated internal stresses due to
fast solidification of the melt during fabrication (also influence by shape part
laser scanning strategy etc)
Part roughness must by adjusted to application req (as manufactured = 10-20 Ra)
eg heat treatments
Electrochemical processes
Laser assisted (eg laser beam
machining)
Grindingpolishing
Fatigue life improvement and roughness improvement
Shot Peening
Laser Peening
Electron Beam hardening
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
NDT inspections 100 full volume
copy GKN Aerospace
Optimized A380
bracket copy EADS
Innovation Works
Optimized A320 bracket
copy EADS Innovation Works
CFRP Load Introduction Rib
copy Airbone Aerospace
Advanced NDI methods
Available during product
development stages
ALM inner porosity
dimensional distortion
(internal stresses) etc
must be analyzed
CFRP fixtures eg radii
inspections requires of
complex and time
consuming UT inspections
Computed Tomography
reliable method for product
development and complex
inspections
2D Cross-sections
X-Ray Tube
Rotating stage
Detector
Specimen
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography
Inner features
3D-Reconstruction
Object surface
Materials characterization
NDT
Metrology
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography ndash Application examples
Actual to Nominal Comparison Inner features
Variance distribution
ALM part for
clampband ARIANE5
3D Characterization
Porosity ~5 ~2 lt05
CASA-ESPACIOCATEC 3D View
Cross
section
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Application Example
FLPP Systems 22
Additive Layer Manufacturing ndash ALM
FLPPCTMampSALM (ITT AQ1-7103)
Evaluation of the potential benefits (and drawbacks) of a designed
combination of ALM technology materials and applications for future
launchers and next generation of space hardware
Design of more efficient parts (aprox 19000euroKg)
ldquoDecrease manufacturing costsrdquo
Design leading technology (ALM)
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Identification of potential target
applications in Launcher Vehicles and ALM
Technology assessment
ARIANE 5 Launcher Structural Stages with EADS CASA-
ESPACIO participation
ALM Project Logic
Phase 1 (finished)
Screening for target application
Phase 2 (finished)
Mechanical characterization and
advanced NDT
Definition of development
and verification plan
Phase 3 (in progress)
Execution of technology
development and verification
plan
Preliminary Breadboard
definition and topological
optimization
Phase 4 (in progress) Phase 5 (not started)
Manufacturing
amp Verification
Composites - Manufacturing today
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
(1) Innovative processing Advanced Manufacturing
(2) Adaptive and smart manufacturing systems
(3) Digital virtual and resource-efficient factories
(4) Collaborative and mobile enterprises (5) Human centric manufacturing and (6) Costumer focused mnf
Research and innovation priorities (H2020)
Raw Material Pre-preg
Vacuum Bag Autoclave
Curing
Out Of Autoclave
Repairs + Automation
SHM
Finishing
NDT + automation
NDT + automation
NDT + automation
Joining and Assembly
Repairs + Automation
SHM
New possibilities
Automation
Automated inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Source TECNATOM SA
Source TECNATOM SA
Multi Robot inspection (ultrasonics)
Non-contact Laser UT
Target Increase flexibility
- Automated flexible process - Object and NDT system manipultation
- Non-contact inspections - Data acquisition and processing
- Quantitative analysis and evaluation
Dimensional analysis
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Contactless 3D reconstruction
Path optimization
Control
Positioning
Acquisition
Location
CCD cameras
Interior Inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Reduced work space
Detection of indications objects and
leakages
Source OC Robotics
(wwwocroboticscom)
Project
subcontractor
Composites - Monitoring
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Structural Health monitoring of
aerostructures during
In service
bonded embedded
Application example FBG Real time signal Data processing strategies
Scheduled maintenance
Manufacturing
Composites ndash Aging
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Effect of environmental factors on composite life
eg temperature humidity oxygen 500 cycles oxidative 30 cycles inert
300 cycles
inert+
ldquoTrdquo CFRP profile
Temperature +
Vibration + load
Sample level
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
Additive Layer Manufacturing - Fundamentals
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Near Net shape manufacturing
3D complex geometries
Topological optimization
(same functions with optimized weight)
Available commercial aerospace materials
Lower product development costs
Green technology
Stainless Steel AISI316L
Antennas IF Brackets
CASA-ESPACIO
CATEC
ALM ndash Topology Optimization
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
ALM Perfect application for topology optimization Topology
optimization has to be lsquointerpretedrsquo and sacrifices in the design
have to be made for conventional manufacturability
Source copy Altair Engineering EADS Innovation Works Topology Optimization of an Additive Layer Manufactured (ALM) Aerospace Part
A320 nacelle hinge bracket
FEA of original part at
max stress cases
FEA of optimized
ALM part
gt60 weight
reduction
Materials
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Commercial Available Metallic Materials (eg Renishaw)
EADS Innovation Works ScalmalloyregRP (AlMgSc) 6061 Morris
Future developments
- Aerospace alloys
- Metal Matrix Composites (eg particle reinforcements)
- Nano Reinforced Materials (Metallic and Polymer base materials)
Ultimate Tensile [MPa]
SLM ldquoconventionalrdquo
ST 900-955degC
Aged 540degC
1130 1170
Stress Relief
1200degF 3 hours
vacuum
Post treatments
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Parts manufactured by ALM presents accumulated internal stresses due to
fast solidification of the melt during fabrication (also influence by shape part
laser scanning strategy etc)
Part roughness must by adjusted to application req (as manufactured = 10-20 Ra)
eg heat treatments
Electrochemical processes
Laser assisted (eg laser beam
machining)
Grindingpolishing
Fatigue life improvement and roughness improvement
Shot Peening
Laser Peening
Electron Beam hardening
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
NDT inspections 100 full volume
copy GKN Aerospace
Optimized A380
bracket copy EADS
Innovation Works
Optimized A320 bracket
copy EADS Innovation Works
CFRP Load Introduction Rib
copy Airbone Aerospace
Advanced NDI methods
Available during product
development stages
ALM inner porosity
dimensional distortion
(internal stresses) etc
must be analyzed
CFRP fixtures eg radii
inspections requires of
complex and time
consuming UT inspections
Computed Tomography
reliable method for product
development and complex
inspections
2D Cross-sections
X-Ray Tube
Rotating stage
Detector
Specimen
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography
Inner features
3D-Reconstruction
Object surface
Materials characterization
NDT
Metrology
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography ndash Application examples
Actual to Nominal Comparison Inner features
Variance distribution
ALM part for
clampband ARIANE5
3D Characterization
Porosity ~5 ~2 lt05
CASA-ESPACIOCATEC 3D View
Cross
section
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Application Example
FLPP Systems 22
Additive Layer Manufacturing ndash ALM
FLPPCTMampSALM (ITT AQ1-7103)
Evaluation of the potential benefits (and drawbacks) of a designed
combination of ALM technology materials and applications for future
launchers and next generation of space hardware
Design of more efficient parts (aprox 19000euroKg)
ldquoDecrease manufacturing costsrdquo
Design leading technology (ALM)
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Identification of potential target
applications in Launcher Vehicles and ALM
Technology assessment
ARIANE 5 Launcher Structural Stages with EADS CASA-
ESPACIO participation
ALM Project Logic
Phase 1 (finished)
Screening for target application
Phase 2 (finished)
Mechanical characterization and
advanced NDT
Definition of development
and verification plan
Phase 3 (in progress)
Execution of technology
development and verification
plan
Preliminary Breadboard
definition and topological
optimization
Phase 4 (in progress) Phase 5 (not started)
Manufacturing
amp Verification
Composites - Manufacturing today
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
(1) Innovative processing Advanced Manufacturing
(2) Adaptive and smart manufacturing systems
(3) Digital virtual and resource-efficient factories
(4) Collaborative and mobile enterprises (5) Human centric manufacturing and (6) Costumer focused mnf
Research and innovation priorities (H2020)
Raw Material Pre-preg
Vacuum Bag Autoclave
Curing
Out Of Autoclave
Repairs + Automation
SHM
Finishing
NDT + automation
NDT + automation
NDT + automation
Joining and Assembly
Repairs + Automation
SHM
New possibilities
Automation
Automated inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Source TECNATOM SA
Source TECNATOM SA
Multi Robot inspection (ultrasonics)
Non-contact Laser UT
Target Increase flexibility
- Automated flexible process - Object and NDT system manipultation
- Non-contact inspections - Data acquisition and processing
- Quantitative analysis and evaluation
Dimensional analysis
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Contactless 3D reconstruction
Path optimization
Control
Positioning
Acquisition
Location
CCD cameras
Interior Inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Reduced work space
Detection of indications objects and
leakages
Source OC Robotics
(wwwocroboticscom)
Project
subcontractor
Composites - Monitoring
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Structural Health monitoring of
aerostructures during
In service
bonded embedded
Application example FBG Real time signal Data processing strategies
Scheduled maintenance
Manufacturing
Composites ndash Aging
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Effect of environmental factors on composite life
eg temperature humidity oxygen 500 cycles oxidative 30 cycles inert
300 cycles
inert+
ldquoTrdquo CFRP profile
Temperature +
Vibration + load
Sample level
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
ALM ndash Topology Optimization
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
ALM Perfect application for topology optimization Topology
optimization has to be lsquointerpretedrsquo and sacrifices in the design
have to be made for conventional manufacturability
Source copy Altair Engineering EADS Innovation Works Topology Optimization of an Additive Layer Manufactured (ALM) Aerospace Part
A320 nacelle hinge bracket
FEA of original part at
max stress cases
FEA of optimized
ALM part
gt60 weight
reduction
Materials
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Commercial Available Metallic Materials (eg Renishaw)
EADS Innovation Works ScalmalloyregRP (AlMgSc) 6061 Morris
Future developments
- Aerospace alloys
- Metal Matrix Composites (eg particle reinforcements)
- Nano Reinforced Materials (Metallic and Polymer base materials)
Ultimate Tensile [MPa]
SLM ldquoconventionalrdquo
ST 900-955degC
Aged 540degC
1130 1170
Stress Relief
1200degF 3 hours
vacuum
Post treatments
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Parts manufactured by ALM presents accumulated internal stresses due to
fast solidification of the melt during fabrication (also influence by shape part
laser scanning strategy etc)
Part roughness must by adjusted to application req (as manufactured = 10-20 Ra)
eg heat treatments
Electrochemical processes
Laser assisted (eg laser beam
machining)
Grindingpolishing
Fatigue life improvement and roughness improvement
Shot Peening
Laser Peening
Electron Beam hardening
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
NDT inspections 100 full volume
copy GKN Aerospace
Optimized A380
bracket copy EADS
Innovation Works
Optimized A320 bracket
copy EADS Innovation Works
CFRP Load Introduction Rib
copy Airbone Aerospace
Advanced NDI methods
Available during product
development stages
ALM inner porosity
dimensional distortion
(internal stresses) etc
must be analyzed
CFRP fixtures eg radii
inspections requires of
complex and time
consuming UT inspections
Computed Tomography
reliable method for product
development and complex
inspections
2D Cross-sections
X-Ray Tube
Rotating stage
Detector
Specimen
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography
Inner features
3D-Reconstruction
Object surface
Materials characterization
NDT
Metrology
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography ndash Application examples
Actual to Nominal Comparison Inner features
Variance distribution
ALM part for
clampband ARIANE5
3D Characterization
Porosity ~5 ~2 lt05
CASA-ESPACIOCATEC 3D View
Cross
section
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Application Example
FLPP Systems 22
Additive Layer Manufacturing ndash ALM
FLPPCTMampSALM (ITT AQ1-7103)
Evaluation of the potential benefits (and drawbacks) of a designed
combination of ALM technology materials and applications for future
launchers and next generation of space hardware
Design of more efficient parts (aprox 19000euroKg)
ldquoDecrease manufacturing costsrdquo
Design leading technology (ALM)
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Identification of potential target
applications in Launcher Vehicles and ALM
Technology assessment
ARIANE 5 Launcher Structural Stages with EADS CASA-
ESPACIO participation
ALM Project Logic
Phase 1 (finished)
Screening for target application
Phase 2 (finished)
Mechanical characterization and
advanced NDT
Definition of development
and verification plan
Phase 3 (in progress)
Execution of technology
development and verification
plan
Preliminary Breadboard
definition and topological
optimization
Phase 4 (in progress) Phase 5 (not started)
Manufacturing
amp Verification
Composites - Manufacturing today
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
(1) Innovative processing Advanced Manufacturing
(2) Adaptive and smart manufacturing systems
(3) Digital virtual and resource-efficient factories
(4) Collaborative and mobile enterprises (5) Human centric manufacturing and (6) Costumer focused mnf
Research and innovation priorities (H2020)
Raw Material Pre-preg
Vacuum Bag Autoclave
Curing
Out Of Autoclave
Repairs + Automation
SHM
Finishing
NDT + automation
NDT + automation
NDT + automation
Joining and Assembly
Repairs + Automation
SHM
New possibilities
Automation
Automated inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Source TECNATOM SA
Source TECNATOM SA
Multi Robot inspection (ultrasonics)
Non-contact Laser UT
Target Increase flexibility
- Automated flexible process - Object and NDT system manipultation
- Non-contact inspections - Data acquisition and processing
- Quantitative analysis and evaluation
Dimensional analysis
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Contactless 3D reconstruction
Path optimization
Control
Positioning
Acquisition
Location
CCD cameras
Interior Inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Reduced work space
Detection of indications objects and
leakages
Source OC Robotics
(wwwocroboticscom)
Project
subcontractor
Composites - Monitoring
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Structural Health monitoring of
aerostructures during
In service
bonded embedded
Application example FBG Real time signal Data processing strategies
Scheduled maintenance
Manufacturing
Composites ndash Aging
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Effect of environmental factors on composite life
eg temperature humidity oxygen 500 cycles oxidative 30 cycles inert
300 cycles
inert+
ldquoTrdquo CFRP profile
Temperature +
Vibration + load
Sample level
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
Materials
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Commercial Available Metallic Materials (eg Renishaw)
EADS Innovation Works ScalmalloyregRP (AlMgSc) 6061 Morris
Future developments
- Aerospace alloys
- Metal Matrix Composites (eg particle reinforcements)
- Nano Reinforced Materials (Metallic and Polymer base materials)
Ultimate Tensile [MPa]
SLM ldquoconventionalrdquo
ST 900-955degC
Aged 540degC
1130 1170
Stress Relief
1200degF 3 hours
vacuum
Post treatments
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Parts manufactured by ALM presents accumulated internal stresses due to
fast solidification of the melt during fabrication (also influence by shape part
laser scanning strategy etc)
Part roughness must by adjusted to application req (as manufactured = 10-20 Ra)
eg heat treatments
Electrochemical processes
Laser assisted (eg laser beam
machining)
Grindingpolishing
Fatigue life improvement and roughness improvement
Shot Peening
Laser Peening
Electron Beam hardening
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
NDT inspections 100 full volume
copy GKN Aerospace
Optimized A380
bracket copy EADS
Innovation Works
Optimized A320 bracket
copy EADS Innovation Works
CFRP Load Introduction Rib
copy Airbone Aerospace
Advanced NDI methods
Available during product
development stages
ALM inner porosity
dimensional distortion
(internal stresses) etc
must be analyzed
CFRP fixtures eg radii
inspections requires of
complex and time
consuming UT inspections
Computed Tomography
reliable method for product
development and complex
inspections
2D Cross-sections
X-Ray Tube
Rotating stage
Detector
Specimen
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography
Inner features
3D-Reconstruction
Object surface
Materials characterization
NDT
Metrology
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography ndash Application examples
Actual to Nominal Comparison Inner features
Variance distribution
ALM part for
clampband ARIANE5
3D Characterization
Porosity ~5 ~2 lt05
CASA-ESPACIOCATEC 3D View
Cross
section
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Application Example
FLPP Systems 22
Additive Layer Manufacturing ndash ALM
FLPPCTMampSALM (ITT AQ1-7103)
Evaluation of the potential benefits (and drawbacks) of a designed
combination of ALM technology materials and applications for future
launchers and next generation of space hardware
Design of more efficient parts (aprox 19000euroKg)
ldquoDecrease manufacturing costsrdquo
Design leading technology (ALM)
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Identification of potential target
applications in Launcher Vehicles and ALM
Technology assessment
ARIANE 5 Launcher Structural Stages with EADS CASA-
ESPACIO participation
ALM Project Logic
Phase 1 (finished)
Screening for target application
Phase 2 (finished)
Mechanical characterization and
advanced NDT
Definition of development
and verification plan
Phase 3 (in progress)
Execution of technology
development and verification
plan
Preliminary Breadboard
definition and topological
optimization
Phase 4 (in progress) Phase 5 (not started)
Manufacturing
amp Verification
Composites - Manufacturing today
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
(1) Innovative processing Advanced Manufacturing
(2) Adaptive and smart manufacturing systems
(3) Digital virtual and resource-efficient factories
(4) Collaborative and mobile enterprises (5) Human centric manufacturing and (6) Costumer focused mnf
Research and innovation priorities (H2020)
Raw Material Pre-preg
Vacuum Bag Autoclave
Curing
Out Of Autoclave
Repairs + Automation
SHM
Finishing
NDT + automation
NDT + automation
NDT + automation
Joining and Assembly
Repairs + Automation
SHM
New possibilities
Automation
Automated inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Source TECNATOM SA
Source TECNATOM SA
Multi Robot inspection (ultrasonics)
Non-contact Laser UT
Target Increase flexibility
- Automated flexible process - Object and NDT system manipultation
- Non-contact inspections - Data acquisition and processing
- Quantitative analysis and evaluation
Dimensional analysis
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Contactless 3D reconstruction
Path optimization
Control
Positioning
Acquisition
Location
CCD cameras
Interior Inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Reduced work space
Detection of indications objects and
leakages
Source OC Robotics
(wwwocroboticscom)
Project
subcontractor
Composites - Monitoring
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Structural Health monitoring of
aerostructures during
In service
bonded embedded
Application example FBG Real time signal Data processing strategies
Scheduled maintenance
Manufacturing
Composites ndash Aging
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Effect of environmental factors on composite life
eg temperature humidity oxygen 500 cycles oxidative 30 cycles inert
300 cycles
inert+
ldquoTrdquo CFRP profile
Temperature +
Vibration + load
Sample level
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
Post treatments
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Parts manufactured by ALM presents accumulated internal stresses due to
fast solidification of the melt during fabrication (also influence by shape part
laser scanning strategy etc)
Part roughness must by adjusted to application req (as manufactured = 10-20 Ra)
eg heat treatments
Electrochemical processes
Laser assisted (eg laser beam
machining)
Grindingpolishing
Fatigue life improvement and roughness improvement
Shot Peening
Laser Peening
Electron Beam hardening
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
NDT inspections 100 full volume
copy GKN Aerospace
Optimized A380
bracket copy EADS
Innovation Works
Optimized A320 bracket
copy EADS Innovation Works
CFRP Load Introduction Rib
copy Airbone Aerospace
Advanced NDI methods
Available during product
development stages
ALM inner porosity
dimensional distortion
(internal stresses) etc
must be analyzed
CFRP fixtures eg radii
inspections requires of
complex and time
consuming UT inspections
Computed Tomography
reliable method for product
development and complex
inspections
2D Cross-sections
X-Ray Tube
Rotating stage
Detector
Specimen
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography
Inner features
3D-Reconstruction
Object surface
Materials characterization
NDT
Metrology
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography ndash Application examples
Actual to Nominal Comparison Inner features
Variance distribution
ALM part for
clampband ARIANE5
3D Characterization
Porosity ~5 ~2 lt05
CASA-ESPACIOCATEC 3D View
Cross
section
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Application Example
FLPP Systems 22
Additive Layer Manufacturing ndash ALM
FLPPCTMampSALM (ITT AQ1-7103)
Evaluation of the potential benefits (and drawbacks) of a designed
combination of ALM technology materials and applications for future
launchers and next generation of space hardware
Design of more efficient parts (aprox 19000euroKg)
ldquoDecrease manufacturing costsrdquo
Design leading technology (ALM)
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Identification of potential target
applications in Launcher Vehicles and ALM
Technology assessment
ARIANE 5 Launcher Structural Stages with EADS CASA-
ESPACIO participation
ALM Project Logic
Phase 1 (finished)
Screening for target application
Phase 2 (finished)
Mechanical characterization and
advanced NDT
Definition of development
and verification plan
Phase 3 (in progress)
Execution of technology
development and verification
plan
Preliminary Breadboard
definition and topological
optimization
Phase 4 (in progress) Phase 5 (not started)
Manufacturing
amp Verification
Composites - Manufacturing today
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
(1) Innovative processing Advanced Manufacturing
(2) Adaptive and smart manufacturing systems
(3) Digital virtual and resource-efficient factories
(4) Collaborative and mobile enterprises (5) Human centric manufacturing and (6) Costumer focused mnf
Research and innovation priorities (H2020)
Raw Material Pre-preg
Vacuum Bag Autoclave
Curing
Out Of Autoclave
Repairs + Automation
SHM
Finishing
NDT + automation
NDT + automation
NDT + automation
Joining and Assembly
Repairs + Automation
SHM
New possibilities
Automation
Automated inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Source TECNATOM SA
Source TECNATOM SA
Multi Robot inspection (ultrasonics)
Non-contact Laser UT
Target Increase flexibility
- Automated flexible process - Object and NDT system manipultation
- Non-contact inspections - Data acquisition and processing
- Quantitative analysis and evaluation
Dimensional analysis
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Contactless 3D reconstruction
Path optimization
Control
Positioning
Acquisition
Location
CCD cameras
Interior Inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Reduced work space
Detection of indications objects and
leakages
Source OC Robotics
(wwwocroboticscom)
Project
subcontractor
Composites - Monitoring
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Structural Health monitoring of
aerostructures during
In service
bonded embedded
Application example FBG Real time signal Data processing strategies
Scheduled maintenance
Manufacturing
Composites ndash Aging
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Effect of environmental factors on composite life
eg temperature humidity oxygen 500 cycles oxidative 30 cycles inert
300 cycles
inert+
ldquoTrdquo CFRP profile
Temperature +
Vibration + load
Sample level
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
NDT inspections 100 full volume
copy GKN Aerospace
Optimized A380
bracket copy EADS
Innovation Works
Optimized A320 bracket
copy EADS Innovation Works
CFRP Load Introduction Rib
copy Airbone Aerospace
Advanced NDI methods
Available during product
development stages
ALM inner porosity
dimensional distortion
(internal stresses) etc
must be analyzed
CFRP fixtures eg radii
inspections requires of
complex and time
consuming UT inspections
Computed Tomography
reliable method for product
development and complex
inspections
2D Cross-sections
X-Ray Tube
Rotating stage
Detector
Specimen
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography
Inner features
3D-Reconstruction
Object surface
Materials characterization
NDT
Metrology
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography ndash Application examples
Actual to Nominal Comparison Inner features
Variance distribution
ALM part for
clampband ARIANE5
3D Characterization
Porosity ~5 ~2 lt05
CASA-ESPACIOCATEC 3D View
Cross
section
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Application Example
FLPP Systems 22
Additive Layer Manufacturing ndash ALM
FLPPCTMampSALM (ITT AQ1-7103)
Evaluation of the potential benefits (and drawbacks) of a designed
combination of ALM technology materials and applications for future
launchers and next generation of space hardware
Design of more efficient parts (aprox 19000euroKg)
ldquoDecrease manufacturing costsrdquo
Design leading technology (ALM)
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Identification of potential target
applications in Launcher Vehicles and ALM
Technology assessment
ARIANE 5 Launcher Structural Stages with EADS CASA-
ESPACIO participation
ALM Project Logic
Phase 1 (finished)
Screening for target application
Phase 2 (finished)
Mechanical characterization and
advanced NDT
Definition of development
and verification plan
Phase 3 (in progress)
Execution of technology
development and verification
plan
Preliminary Breadboard
definition and topological
optimization
Phase 4 (in progress) Phase 5 (not started)
Manufacturing
amp Verification
Composites - Manufacturing today
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
(1) Innovative processing Advanced Manufacturing
(2) Adaptive and smart manufacturing systems
(3) Digital virtual and resource-efficient factories
(4) Collaborative and mobile enterprises (5) Human centric manufacturing and (6) Costumer focused mnf
Research and innovation priorities (H2020)
Raw Material Pre-preg
Vacuum Bag Autoclave
Curing
Out Of Autoclave
Repairs + Automation
SHM
Finishing
NDT + automation
NDT + automation
NDT + automation
Joining and Assembly
Repairs + Automation
SHM
New possibilities
Automation
Automated inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Source TECNATOM SA
Source TECNATOM SA
Multi Robot inspection (ultrasonics)
Non-contact Laser UT
Target Increase flexibility
- Automated flexible process - Object and NDT system manipultation
- Non-contact inspections - Data acquisition and processing
- Quantitative analysis and evaluation
Dimensional analysis
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Contactless 3D reconstruction
Path optimization
Control
Positioning
Acquisition
Location
CCD cameras
Interior Inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Reduced work space
Detection of indications objects and
leakages
Source OC Robotics
(wwwocroboticscom)
Project
subcontractor
Composites - Monitoring
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Structural Health monitoring of
aerostructures during
In service
bonded embedded
Application example FBG Real time signal Data processing strategies
Scheduled maintenance
Manufacturing
Composites ndash Aging
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Effect of environmental factors on composite life
eg temperature humidity oxygen 500 cycles oxidative 30 cycles inert
300 cycles
inert+
ldquoTrdquo CFRP profile
Temperature +
Vibration + load
Sample level
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
2D Cross-sections
X-Ray Tube
Rotating stage
Detector
Specimen
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography
Inner features
3D-Reconstruction
Object surface
Materials characterization
NDT
Metrology
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography ndash Application examples
Actual to Nominal Comparison Inner features
Variance distribution
ALM part for
clampband ARIANE5
3D Characterization
Porosity ~5 ~2 lt05
CASA-ESPACIOCATEC 3D View
Cross
section
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Application Example
FLPP Systems 22
Additive Layer Manufacturing ndash ALM
FLPPCTMampSALM (ITT AQ1-7103)
Evaluation of the potential benefits (and drawbacks) of a designed
combination of ALM technology materials and applications for future
launchers and next generation of space hardware
Design of more efficient parts (aprox 19000euroKg)
ldquoDecrease manufacturing costsrdquo
Design leading technology (ALM)
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Identification of potential target
applications in Launcher Vehicles and ALM
Technology assessment
ARIANE 5 Launcher Structural Stages with EADS CASA-
ESPACIO participation
ALM Project Logic
Phase 1 (finished)
Screening for target application
Phase 2 (finished)
Mechanical characterization and
advanced NDT
Definition of development
and verification plan
Phase 3 (in progress)
Execution of technology
development and verification
plan
Preliminary Breadboard
definition and topological
optimization
Phase 4 (in progress) Phase 5 (not started)
Manufacturing
amp Verification
Composites - Manufacturing today
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
(1) Innovative processing Advanced Manufacturing
(2) Adaptive and smart manufacturing systems
(3) Digital virtual and resource-efficient factories
(4) Collaborative and mobile enterprises (5) Human centric manufacturing and (6) Costumer focused mnf
Research and innovation priorities (H2020)
Raw Material Pre-preg
Vacuum Bag Autoclave
Curing
Out Of Autoclave
Repairs + Automation
SHM
Finishing
NDT + automation
NDT + automation
NDT + automation
Joining and Assembly
Repairs + Automation
SHM
New possibilities
Automation
Automated inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Source TECNATOM SA
Source TECNATOM SA
Multi Robot inspection (ultrasonics)
Non-contact Laser UT
Target Increase flexibility
- Automated flexible process - Object and NDT system manipultation
- Non-contact inspections - Data acquisition and processing
- Quantitative analysis and evaluation
Dimensional analysis
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Contactless 3D reconstruction
Path optimization
Control
Positioning
Acquisition
Location
CCD cameras
Interior Inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Reduced work space
Detection of indications objects and
leakages
Source OC Robotics
(wwwocroboticscom)
Project
subcontractor
Composites - Monitoring
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Structural Health monitoring of
aerostructures during
In service
bonded embedded
Application example FBG Real time signal Data processing strategies
Scheduled maintenance
Manufacturing
Composites ndash Aging
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Effect of environmental factors on composite life
eg temperature humidity oxygen 500 cycles oxidative 30 cycles inert
300 cycles
inert+
ldquoTrdquo CFRP profile
Temperature +
Vibration + load
Sample level
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
Inspection of Free Form geometries
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
X-Ray Computed Tomography ndash Application examples
Actual to Nominal Comparison Inner features
Variance distribution
ALM part for
clampband ARIANE5
3D Characterization
Porosity ~5 ~2 lt05
CASA-ESPACIOCATEC 3D View
Cross
section
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Application Example
FLPP Systems 22
Additive Layer Manufacturing ndash ALM
FLPPCTMampSALM (ITT AQ1-7103)
Evaluation of the potential benefits (and drawbacks) of a designed
combination of ALM technology materials and applications for future
launchers and next generation of space hardware
Design of more efficient parts (aprox 19000euroKg)
ldquoDecrease manufacturing costsrdquo
Design leading technology (ALM)
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Identification of potential target
applications in Launcher Vehicles and ALM
Technology assessment
ARIANE 5 Launcher Structural Stages with EADS CASA-
ESPACIO participation
ALM Project Logic
Phase 1 (finished)
Screening for target application
Phase 2 (finished)
Mechanical characterization and
advanced NDT
Definition of development
and verification plan
Phase 3 (in progress)
Execution of technology
development and verification
plan
Preliminary Breadboard
definition and topological
optimization
Phase 4 (in progress) Phase 5 (not started)
Manufacturing
amp Verification
Composites - Manufacturing today
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
(1) Innovative processing Advanced Manufacturing
(2) Adaptive and smart manufacturing systems
(3) Digital virtual and resource-efficient factories
(4) Collaborative and mobile enterprises (5) Human centric manufacturing and (6) Costumer focused mnf
Research and innovation priorities (H2020)
Raw Material Pre-preg
Vacuum Bag Autoclave
Curing
Out Of Autoclave
Repairs + Automation
SHM
Finishing
NDT + automation
NDT + automation
NDT + automation
Joining and Assembly
Repairs + Automation
SHM
New possibilities
Automation
Automated inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Source TECNATOM SA
Source TECNATOM SA
Multi Robot inspection (ultrasonics)
Non-contact Laser UT
Target Increase flexibility
- Automated flexible process - Object and NDT system manipultation
- Non-contact inspections - Data acquisition and processing
- Quantitative analysis and evaluation
Dimensional analysis
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Contactless 3D reconstruction
Path optimization
Control
Positioning
Acquisition
Location
CCD cameras
Interior Inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Reduced work space
Detection of indications objects and
leakages
Source OC Robotics
(wwwocroboticscom)
Project
subcontractor
Composites - Monitoring
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Structural Health monitoring of
aerostructures during
In service
bonded embedded
Application example FBG Real time signal Data processing strategies
Scheduled maintenance
Manufacturing
Composites ndash Aging
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Effect of environmental factors on composite life
eg temperature humidity oxygen 500 cycles oxidative 30 cycles inert
300 cycles
inert+
ldquoTrdquo CFRP profile
Temperature +
Vibration + load
Sample level
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Application Example
FLPP Systems 22
Additive Layer Manufacturing ndash ALM
FLPPCTMampSALM (ITT AQ1-7103)
Evaluation of the potential benefits (and drawbacks) of a designed
combination of ALM technology materials and applications for future
launchers and next generation of space hardware
Design of more efficient parts (aprox 19000euroKg)
ldquoDecrease manufacturing costsrdquo
Design leading technology (ALM)
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Identification of potential target
applications in Launcher Vehicles and ALM
Technology assessment
ARIANE 5 Launcher Structural Stages with EADS CASA-
ESPACIO participation
ALM Project Logic
Phase 1 (finished)
Screening for target application
Phase 2 (finished)
Mechanical characterization and
advanced NDT
Definition of development
and verification plan
Phase 3 (in progress)
Execution of technology
development and verification
plan
Preliminary Breadboard
definition and topological
optimization
Phase 4 (in progress) Phase 5 (not started)
Manufacturing
amp Verification
Composites - Manufacturing today
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
(1) Innovative processing Advanced Manufacturing
(2) Adaptive and smart manufacturing systems
(3) Digital virtual and resource-efficient factories
(4) Collaborative and mobile enterprises (5) Human centric manufacturing and (6) Costumer focused mnf
Research and innovation priorities (H2020)
Raw Material Pre-preg
Vacuum Bag Autoclave
Curing
Out Of Autoclave
Repairs + Automation
SHM
Finishing
NDT + automation
NDT + automation
NDT + automation
Joining and Assembly
Repairs + Automation
SHM
New possibilities
Automation
Automated inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Source TECNATOM SA
Source TECNATOM SA
Multi Robot inspection (ultrasonics)
Non-contact Laser UT
Target Increase flexibility
- Automated flexible process - Object and NDT system manipultation
- Non-contact inspections - Data acquisition and processing
- Quantitative analysis and evaluation
Dimensional analysis
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Contactless 3D reconstruction
Path optimization
Control
Positioning
Acquisition
Location
CCD cameras
Interior Inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Reduced work space
Detection of indications objects and
leakages
Source OC Robotics
(wwwocroboticscom)
Project
subcontractor
Composites - Monitoring
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Structural Health monitoring of
aerostructures during
In service
bonded embedded
Application example FBG Real time signal Data processing strategies
Scheduled maintenance
Manufacturing
Composites ndash Aging
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Effect of environmental factors on composite life
eg temperature humidity oxygen 500 cycles oxidative 30 cycles inert
300 cycles
inert+
ldquoTrdquo CFRP profile
Temperature +
Vibration + load
Sample level
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
ALM in Space
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Identification of potential target
applications in Launcher Vehicles and ALM
Technology assessment
ARIANE 5 Launcher Structural Stages with EADS CASA-
ESPACIO participation
ALM Project Logic
Phase 1 (finished)
Screening for target application
Phase 2 (finished)
Mechanical characterization and
advanced NDT
Definition of development
and verification plan
Phase 3 (in progress)
Execution of technology
development and verification
plan
Preliminary Breadboard
definition and topological
optimization
Phase 4 (in progress) Phase 5 (not started)
Manufacturing
amp Verification
Composites - Manufacturing today
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
(1) Innovative processing Advanced Manufacturing
(2) Adaptive and smart manufacturing systems
(3) Digital virtual and resource-efficient factories
(4) Collaborative and mobile enterprises (5) Human centric manufacturing and (6) Costumer focused mnf
Research and innovation priorities (H2020)
Raw Material Pre-preg
Vacuum Bag Autoclave
Curing
Out Of Autoclave
Repairs + Automation
SHM
Finishing
NDT + automation
NDT + automation
NDT + automation
Joining and Assembly
Repairs + Automation
SHM
New possibilities
Automation
Automated inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Source TECNATOM SA
Source TECNATOM SA
Multi Robot inspection (ultrasonics)
Non-contact Laser UT
Target Increase flexibility
- Automated flexible process - Object and NDT system manipultation
- Non-contact inspections - Data acquisition and processing
- Quantitative analysis and evaluation
Dimensional analysis
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Contactless 3D reconstruction
Path optimization
Control
Positioning
Acquisition
Location
CCD cameras
Interior Inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Reduced work space
Detection of indications objects and
leakages
Source OC Robotics
(wwwocroboticscom)
Project
subcontractor
Composites - Monitoring
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Structural Health monitoring of
aerostructures during
In service
bonded embedded
Application example FBG Real time signal Data processing strategies
Scheduled maintenance
Manufacturing
Composites ndash Aging
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Effect of environmental factors on composite life
eg temperature humidity oxygen 500 cycles oxidative 30 cycles inert
300 cycles
inert+
ldquoTrdquo CFRP profile
Temperature +
Vibration + load
Sample level
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
Composites - Manufacturing today
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
(1) Innovative processing Advanced Manufacturing
(2) Adaptive and smart manufacturing systems
(3) Digital virtual and resource-efficient factories
(4) Collaborative and mobile enterprises (5) Human centric manufacturing and (6) Costumer focused mnf
Research and innovation priorities (H2020)
Raw Material Pre-preg
Vacuum Bag Autoclave
Curing
Out Of Autoclave
Repairs + Automation
SHM
Finishing
NDT + automation
NDT + automation
NDT + automation
Joining and Assembly
Repairs + Automation
SHM
New possibilities
Automation
Automated inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Source TECNATOM SA
Source TECNATOM SA
Multi Robot inspection (ultrasonics)
Non-contact Laser UT
Target Increase flexibility
- Automated flexible process - Object and NDT system manipultation
- Non-contact inspections - Data acquisition and processing
- Quantitative analysis and evaluation
Dimensional analysis
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Contactless 3D reconstruction
Path optimization
Control
Positioning
Acquisition
Location
CCD cameras
Interior Inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Reduced work space
Detection of indications objects and
leakages
Source OC Robotics
(wwwocroboticscom)
Project
subcontractor
Composites - Monitoring
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Structural Health monitoring of
aerostructures during
In service
bonded embedded
Application example FBG Real time signal Data processing strategies
Scheduled maintenance
Manufacturing
Composites ndash Aging
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Effect of environmental factors on composite life
eg temperature humidity oxygen 500 cycles oxidative 30 cycles inert
300 cycles
inert+
ldquoTrdquo CFRP profile
Temperature +
Vibration + load
Sample level
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
Automated inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Source TECNATOM SA
Source TECNATOM SA
Multi Robot inspection (ultrasonics)
Non-contact Laser UT
Target Increase flexibility
- Automated flexible process - Object and NDT system manipultation
- Non-contact inspections - Data acquisition and processing
- Quantitative analysis and evaluation
Dimensional analysis
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Contactless 3D reconstruction
Path optimization
Control
Positioning
Acquisition
Location
CCD cameras
Interior Inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Reduced work space
Detection of indications objects and
leakages
Source OC Robotics
(wwwocroboticscom)
Project
subcontractor
Composites - Monitoring
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Structural Health monitoring of
aerostructures during
In service
bonded embedded
Application example FBG Real time signal Data processing strategies
Scheduled maintenance
Manufacturing
Composites ndash Aging
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Effect of environmental factors on composite life
eg temperature humidity oxygen 500 cycles oxidative 30 cycles inert
300 cycles
inert+
ldquoTrdquo CFRP profile
Temperature +
Vibration + load
Sample level
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
Dimensional analysis
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Contactless 3D reconstruction
Path optimization
Control
Positioning
Acquisition
Location
CCD cameras
Interior Inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Reduced work space
Detection of indications objects and
leakages
Source OC Robotics
(wwwocroboticscom)
Project
subcontractor
Composites - Monitoring
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Structural Health monitoring of
aerostructures during
In service
bonded embedded
Application example FBG Real time signal Data processing strategies
Scheduled maintenance
Manufacturing
Composites ndash Aging
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Effect of environmental factors on composite life
eg temperature humidity oxygen 500 cycles oxidative 30 cycles inert
300 cycles
inert+
ldquoTrdquo CFRP profile
Temperature +
Vibration + load
Sample level
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
Interior Inspections
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Reduced work space
Detection of indications objects and
leakages
Source OC Robotics
(wwwocroboticscom)
Project
subcontractor
Composites - Monitoring
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Structural Health monitoring of
aerostructures during
In service
bonded embedded
Application example FBG Real time signal Data processing strategies
Scheduled maintenance
Manufacturing
Composites ndash Aging
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Effect of environmental factors on composite life
eg temperature humidity oxygen 500 cycles oxidative 30 cycles inert
300 cycles
inert+
ldquoTrdquo CFRP profile
Temperature +
Vibration + load
Sample level
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
Composites - Monitoring
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Structural Health monitoring of
aerostructures during
In service
bonded embedded
Application example FBG Real time signal Data processing strategies
Scheduled maintenance
Manufacturing
Composites ndash Aging
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Effect of environmental factors on composite life
eg temperature humidity oxygen 500 cycles oxidative 30 cycles inert
300 cycles
inert+
ldquoTrdquo CFRP profile
Temperature +
Vibration + load
Sample level
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
Composites ndash Aging
Dic 2013 Inspiring Day Industria y Faacutebrica del Futuro Fernando Lasagni flasagnicatecaero
Effect of environmental factors on composite life
eg temperature humidity oxygen 500 cycles oxidative 30 cycles inert
300 cycles
inert+
ldquoTrdquo CFRP profile
Temperature +
Vibration + load
Sample level
Mechanical
characterization
Relationship
between highly
accelerated aging
cycles and fatigue
behaviour
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
Prospects and Challenges of Additive Manufacturing
and Process Automation in the Aerospace Industry
Andalusian Foundation for Aerospace Development (FADA)
Center for Advanced Aerospace Technologies (CATEC)
Juan Pedro Vela General Manager
Carlos Peacuterez Head of Automation amp Robotics
Fernando A Lasagni Head of Materials amp Processes
