Additive manufacturing: Next generation OEM &

sustainment solutions

Kyle Spieles & Juan Lara

May 9-10, 2018

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Agenda
The value proposition for AM

Eaton’s team and capability

Metal material characterization status

High temp. polymer material development

Aftermarket strategy

Outcome: Awareness of Eaton’s plan and progress relative to metallic and composite additive manufacturing
and rapid repair

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Value proposition for additive manufacturing
Value proposition can include one or more

Speed Cost Improved performance

 Rapid product development  Reduced infrastructure  15-25% less weight

 Eliminate tooling  Material efficiency  Improved performance
 Reduced supply chain  Enable repair vs. replace  Increased time between
 Direct print production parts  Inventory reduction maintenance

 Part consolidation  Package size

The value from additive is more than just part to part cost savings.

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Eaton’s Additive Manufacturing journey
Eaton opens Designing clean sheet solutions
AM COE Aftermarket solutions
Low rate initial production
Material expertise
Qualification of AM parts
Part consolidation
Internal geometries for
fluid / thermal management

2013-2015 2016 2017 2018-2020

Jigs, Fixtures, rapid Topology optimization
prototyping, for light weighting
advanced Launch Aerospace AM Team
nanocomposite
development - PAEK Eaton introduces
Hydropower AM
Concept

Eaton has been focusing in building capability, deploying technology and gaining credibility

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Eaton’s Additive Manufacturing
team a global footprint
AM Center of excellence lab & research - Southfield, MI
• 15 Team members

Industrial sector businesses

Aerospace; Hydraulics; Vehicle
• 15 Dedicated team members
Eaton AM Center of excellence lab (R&D)
• ~100 Involved in additive projects AM Team Pune India
• 25 Team members
focused on AM

Electrical business
• 3 Team members

Eaton is expanding the additive manufacturing efforts across multiple divisions and the globe

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Additive Manufacturing operations impact
Pump conventional processes: 37 Operations
Runn Dewa Remo
Wax er Wax Unloa x& ve Water Cut Trim Dry Tensil Dry Machi
Part Bars Asm Shell Slurry d Blast off off Blast HT 1 Set HT 2 Insp e FPI Insp Xray Insp Blast Chem Hard Insp Store ne Store Mark Asm PAT Asm PAT Insp Insp
Wax Cast Shell

Additive process: 14 Operations

Surfa
Rem Band Mach ce Tensi Che
Print ove saw ine le Insp FPI Insp m Hard Asm PAT Clean
Treat

Impact on key metrics by reducing VSM Metrics Impacts

Safety - Eliminate EHS Risks
250%
Quality - In-situ monitoring
200%
produces more quality
150% data

HIGH 5
Current State On Time - Reduced variability
100% Delivery
50% Productivity - Streamlines workflow

0% Inventory / - Streamlines workflow

Output
Parts/year Lead time
Lead Time Head
HeadCount
count Velocity

Additive streamlines the operations, reducing lead time and improving throughput with a smaller workforce.

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Material characterization - Metals
Startup Baseline Extended: 12-36 months
3 months 3-12 months Qual. & Cert: 24-48 months

• Vendor datasheets • Tensile data = f (HT, surf. • Application specific prop.

• Service provider data cond., orient.) • Thermo-physical (r, CTE, Cp, k)
• Fatigue data = f (HT, • Tensile = f(temperature)
• Public domain literature
surf. cond., orient.) • Fatigue = f(load ratio, temp.)
Background data • Toughness, FCGR, Other =
Baseline characterization f(temp., other)
• Opt. Post grow processes
• Alternative HT (if req.)
• Surface finishing
Aluminum and Inconel 718 extended
Extended characterization
characterization expected to be completed Q4
2018 • Proc. & Feedstock variability
• S, B, A basis “allowables”
Titanium extended characterization expected to
be completed Q2 2019 Statistical characterization

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Material characterization – PAEK w/ fillers
Baseline Extended Statistical/Design allowable:
6 months (2018-2018) 6-12 months (2018) 12-36 months (2018-2019)

• Print coupons and • Process optimization studies • Process spec document

straight ducts
• Down select material by
static testing of coupons
and straight ducts
• Flame, Toxicity and
smoke density
• Tensile stress / Strain = • FAA DER Approval for
f (Temp, speed, orient.) Material and process spec
• Fatigue & Creep = f (process, • B, basis “allowable”
orient) (stress R=-1, RT only)
• Thermo-physical (r, CTE,
Cp, k)
• Fluid susceptibility
• Material spec document

Material down selection and material specification to be developed in 2018

Process specification and B-Basis allowable to be developed in 2019

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High temperature Additive Manufacturing

2 ft.

Conventional Additive
55 mfg operations 39 mfg operations
12 components 7 components
6 week lead time ~ 2 week lead time

Print time reduced from Print time of 55 System level benefits

15 to 1.5 hours minutes >20% weight reduction, fewer components

Proven capabilities of printing high temperature composite material with additive manufacturing using FDM.

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Aftermarket deployment strategy
Rapid repair and casting Wear resistant coating Casting replacement and
core replacement (2018) (2018-2020) structural component
repair (2020-2022)

• Develop cold spray process and
other direct energy deposition
techniques of interest
• Printing of sand and investment
cast cores – addressing items
that are out of production or
obsolete
• FAA certification of Eaton • Directly printed aftermarket
cold spray repairs in 2019 castings
• Develop coatings that offer • Structural component repair
performance improvement • Repair non-Eaton products
• Wear
• Cavitation
• Corrosion

Leverage additive manufacturing and repair techniques to reduce TAT, provide novel sustainment solutions, and
increase customer satisfaction

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Cold spray repair process
• Many names: Cold spray, Cold gas-dynamic
spraying, Supersonic particle deposition
• Heated, high pressure gas passes through a
deLaval nozzle to accelerate fine powder at
supersonic velocities against a substrate –
ballistic impingement
• Solid state bonding – no melting
• No heat affected zone
• Minimal / No distortion
• Compressive residual stresses – no need for
post-process heat treatment

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Cold spray repair development
• Cold spray process development is progressing
through 2018 - dimensional restoration
• Multiple military and commercial repair
applications are being developed in 2018 Cold spray video

*Video courtesy of the Army research lab

Finished
repair
ready for
product
testing.

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The ask
• Help us define the major pain points

• Keep Eaton’s Additive Manufacturing capabilities in mind when evaluating

solutions to service issues

Looking for opportunities to develop next generation additive manufacturing solutions with our
customers and partners

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Questions/Comments

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www.eaton.com/aerospace

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