Process Capability Study on the Volume Manufacturing of a Complex Rotating Automotive Component in Laser Powder Bed Fusion Additive Manufacturing

Chase Joslin; Joy Forsmark; Nick Estock; Ryan Dehoff; Peeyush Nandwana; Sammy Passell; Rich Werth; Eric Poczatek; Mark Meinhart; Asim Khan; John Cornell; Greg McConville

doi:10.2172/1975343

Process Capability Study on the Volume Manufacturing of a Complex Rotating Automotive Component in Laser Powder Bed Fusion Additive Manufacturing

Chase Joslin
, Joy Forsmark
, Nick Estock
, Ryan Dehoff
, Peeyush Nandwana
, Sammy Passell
, Rich Werth
, Eric Poczatek
, Mark Meinhart
, Asim Khan
, John Cornell
, Greg McConville

Research output: Other contribution › Technical Report

Abstract

Oak Ridge National Lab (ORNL) and Ford Motor Company used an AddUp FormUp 350 to print a turbo wheel geometry to show feasibility of laser powder bed fusion (L-PBF) additive manufacturing (AM) in producing cost-effective components for automotive industries. L-PBF AM has potential to disrupt traditional manufacturing techniques by introducing novel materials and geometries that cannot otherwise be produced. Fundamental challenges associated with L-PBF include limitations on printing overhang geometries and resulting surface finish. In this collaboration, ORNL and Ford partnered with AddUp to show the viability of using L-PBF for an AM design turbine wheel while reducing as-fabricated surface roughness. A cost model associated with mass production was produced to analyze benefits of pursing LPBF AM compared to investment casting.

Original language	English
Place of Publication	United States
DOIs	https://doi.org/10.2172/1975343
State	Published - 2023

Keywords

36 MATERIALS SCIENCE
42 ENGINEERING

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10.2172/1975343

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title = "Process Capability Study on the Volume Manufacturing of a Complex Rotating Automotive Component in Laser Powder Bed Fusion Additive Manufacturing",

abstract = "Oak Ridge National Lab (ORNL) and Ford Motor Company used an AddUp FormUp 350 to print a turbo wheel geometry to show feasibility of laser powder bed fusion (L-PBF) additive manufacturing (AM) in producing cost-effective components for automotive industries. L-PBF AM has potential to disrupt traditional manufacturing techniques by introducing novel materials and geometries that cannot otherwise be produced. Fundamental challenges associated with L-PBF include limitations on printing overhang geometries and resulting surface finish. In this collaboration, ORNL and Ford partnered with AddUp to show the viability of using L-PBF for an AM design turbine wheel while reducing as-fabricated surface roughness. A cost model associated with mass production was produced to analyze benefits of pursing LPBF AM compared to investment casting.",

keywords = "36 MATERIALS SCIENCE, 42 ENGINEERING",

author = "Chase Joslin and Joy Forsmark and Nick Estock and Ryan Dehoff and Peeyush Nandwana and Sammy Passell and Rich Werth and Eric Poczatek and Mark Meinhart and Asim Khan and John Cornell and Greg McConville",

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doi = "10.2172/1975343",

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T1 - Process Capability Study on the Volume Manufacturing of a Complex Rotating Automotive Component in Laser Powder Bed Fusion Additive Manufacturing

AU - Joslin, Chase

AU - Forsmark, Joy

AU - Estock, Nick

AU - Dehoff, Ryan

AU - Nandwana, Peeyush

AU - Passell, Sammy

AU - Werth, Rich

AU - Poczatek, Eric

AU - Meinhart, Mark

AU - Khan, Asim

AU - Cornell, John

AU - McConville, Greg

PY - 2023

Y1 - 2023

N2 - Oak Ridge National Lab (ORNL) and Ford Motor Company used an AddUp FormUp 350 to print a turbo wheel geometry to show feasibility of laser powder bed fusion (L-PBF) additive manufacturing (AM) in producing cost-effective components for automotive industries. L-PBF AM has potential to disrupt traditional manufacturing techniques by introducing novel materials and geometries that cannot otherwise be produced. Fundamental challenges associated with L-PBF include limitations on printing overhang geometries and resulting surface finish. In this collaboration, ORNL and Ford partnered with AddUp to show the viability of using L-PBF for an AM design turbine wheel while reducing as-fabricated surface roughness. A cost model associated with mass production was produced to analyze benefits of pursing LPBF AM compared to investment casting.

AB - Oak Ridge National Lab (ORNL) and Ford Motor Company used an AddUp FormUp 350 to print a turbo wheel geometry to show feasibility of laser powder bed fusion (L-PBF) additive manufacturing (AM) in producing cost-effective components for automotive industries. L-PBF AM has potential to disrupt traditional manufacturing techniques by introducing novel materials and geometries that cannot otherwise be produced. Fundamental challenges associated with L-PBF include limitations on printing overhang geometries and resulting surface finish. In this collaboration, ORNL and Ford partnered with AddUp to show the viability of using L-PBF for an AM design turbine wheel while reducing as-fabricated surface roughness. A cost model associated with mass production was produced to analyze benefits of pursing LPBF AM compared to investment casting.

KW - 36 MATERIALS SCIENCE

KW - 42 ENGINEERING

U2 - 10.2172/1975343

DO - 10.2172/1975343

M3 - Technical Report

CY - United States

ER -

Process Capability Study on the Volume Manufacturing of a Complex Rotating Automotive Component in Laser Powder Bed Fusion Additive Manufacturing

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