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Brings Additive and Subtractive Technologies Together.
How could additive manufacturing (AM) fit into your operation? To show small- and medium-sized manufacturers just a few of the possibilities, the U.S. Department of Energy’s Manufacturing Demonstration Facility at Oak Ridge National Laboratory (ORNL) has created a convergent manufacturing platform that combines metal AM with CNC machining and other familiar processes in an innovative configuration.
The manufacturing platform, presented at the AMT Emerging Technology Center (ETC) booths #236700 and #236905 at IMTS 2024, Sept 9-14 at McCormick Place, Chicago, includes:
- Two wire-arc additive manufacturing (WAAM) systems using arc directed energy deposition (arc DED), a metal AM technology from Lincoln Electric and software from Open Mind (booth #133351).
- Four robots from Yaskawa America (booth #236601).
- A machining center from Okuma (booth #338500), cutting tools provided by Kennametal (booth #432324) and Zoller (booth #432018), and workholding from 5th Axis (booth #431355).
- A Fastems (booth #338966) pallet tower, designed for high-speed transfer of hot work, registration preservation, unmanned operations, and simultaneous production of diverse high-mix components.
- An Ajax Tocco induction heating station for pre-heating and maintaining interpass temperature.
- 3D scanning metrology station from Zeiss (booth #134302).
The integrated platform will host three separate demonstrations daily during IMTS, showcasing how a hybrid production cell could effectively handle conventional tasks like tooling, forging and casting replacement, and gear repair.
Three primary applications constitute the essence of additive technology: tooling, tooling, and more tooling, as each tool involves substantial costs and holds great value. Utilizing 3D printing to craft molds closely resembling the final shape significantly reduces production time in comparison to traditional methods, potentially revolutionizing the tooling sector and boosting domestic production within the United States.
During each day of the IMTS, a distinct demonstration focused on tooling will feature the production of a numbered challenge coin. The procedure includes 3D printing a coin mold, refining the internal surface through machining, and imprinting a numeral indicative of the respective day of the exhibition (ranging from one to six). The coins are then formed using a compact plastic injection molding machine.
“In every mold repair workshop, you will find activities such as welding, grinding, and machining. This is essentially hybrid manufacturing, though it might not be labeled as such by the proprietors,” explains Thomas Feldhausen, a researcher and principal investigator at ORNL. “While an expert might refer to certain processes like arc DED, a typical shop owner might describe it as an adaptation of Gas Metal Arc Welding for additive manufacturing, and they wouldn’t be wrong. By demystifying our processes and presenting them in relatable terms, we aim to foster a greater acceptance and understanding of AM and hybrid manufacturing among the attendees at the IMTS through direct engagements with ORNL experts.”
Casting and Forging
To qualify as a foundry for the U.S. Navy, companies must successfully produce a part known as the “Platypus” (as specified in the NAVSEA T9074-BD-GIB-010_0300 document), which is considered the initial article casting.
“Our funding comes from IBAS, or Industrial Base Policy, which aims to update the U.S. defense industrial base. Therefore, we are developing a component that is crucial for manufacturers aiming to enter the defense sector,” Feldhausen stated. “We start with standard bar stock, then enhance it using arc DED paired with a nickel-aluminum-bronze filler wire.”
According to Feldhausen, ORNL developed the showcased system at the ETC using a modular design. “We collaborated with incredible partners to build the convergent platform, however, we understand that manufacturers may have preferences for different brands. Our system is designed to allow the replacement of any component,” he mentioned. “We aimed to demonstrate the simplicity of integrating this technology in workshops.”
Clean Energy
The final activity at the ETC involves a demonstration on fixing a gear tooth in a wind turbine, a sector that is burgeoning due to increased wind energy utilization (according to the U.S. Energy Information Administration, wind power is expected to increase by 11% from 430 billion kWh in 2023 to 476 billion kWh in 2025). This process involves adding material using AM technology then precisely machining the gear tooth back to its original size.
“The integration of additive and subtractive methods offers significant advantages. Through these demonstrations at the ETC, we aim to motivate manufacturers to enhance their capabilities,” Feldhausen commented.
Feldhausen, an expert in hybrid manufacturing with experience across various systems, often addresses queries like “What’s your favorite AM technology?” or “Which is the best machine to invest in?”
“There are no definitive answers,” he explains. “It all depends on what you need for your specific applications, materials, and goals. At ORNL, we don’t favor any particular technology but focus on assisting individuals in selecting and advancing the most suitable technology for their needs.”
The ETC is situated just outside the Grand Concourse of McCormick Place at the entrance to the North Building, at booths #236700 and #236905. Following interactions with the ORNL specialists, attendees are encouraged to discover additional processes and technologies displayed throughout the IMTS show floor—initially commencing with registration for IMTS 2024.
