Physical Sciences 1 Brief
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High Speed Ceramic Laser Machining Physical Sciences Inc. 20 New England Business Center Andover, MA 01810-1077
Contact: Dr. Mark Druy Phone: (978) 738-8195 Email: [email protected] Website: http://www.psicorp.com Command: NAVAIR Topic: N06-T012
PROBLEM STATEMENT Aircraft engine and exhaust washed structures require highly efficient ceramic matrix composite (CMC) designs to minimize weight and withstand severe environmental conditions. It is time consuming and expensive to fabricate these components, as they require significant post-fabrication machining to precise dimensions. The machining process is very difficult, due to the low thermal conductivity and hard, brittle, abrasive nature of CMCs. As a result of the unique characteristics of CMCs, existing methods of machining and drilling are inefficient and expensive. Machine tools are easily damaged and require frequent replacement due to over-heating and repeated contact with the hard and abrasive material. In addition, the CMC components are prone to damage from improper machining. A high-speed machining process is needed to eliminate many of the major cost and risk impediments for transitioning these materials to aircraft production. PSI is addressing this need by developing a highly innovative high speed laser machining center. The PSI laser machine center is demonstrating machining of CMC components at rates 25 times faster and 1/10 the cost of the original baseline machining techniques. These improvements are cost and time enabling for production of CMC aircraft components. Our technology is currently being qualified in the manufacturing line for a specific Navy platform. The JSF program office is intimately involved with this qualification process.
WHO CAN BENEFIT? Immediate applications for the PSI Laser Machining Center are CMC engine components for JSF and other CMC components for other aircraft platforms. In addition, all systems that want to take advantage of the higher performance, lighter weight and reduced life cycle costs achieved by use of machined CMC and ceramic components will benefit from this Page 1 of 5 Physical Sciences Inc. NAVAIR Public Release 08-1234 Distribution: Statement A - "Approved for public release; distribution unlimited"
technology. This PSI machining technology can be expanded to machine not only additional aircraft components, but also rapid machining of other ceramic materials. Immediate applications are: • • • •
ceramic armor rocket and hypersonic propulsion components advanced aerospace structures value added machining of ceramic net shape processed components
BASELINE TECHNOLOGY The baseline machining technology for ceramic materials is water jet rough cutting or contact machining (milling). Both operations are used at different times, not necessarily in combination. In either operation the components are submerged in coolant, requiring costly and time consuming subsequent cleaning and drying operations. These conventional machining techniques can cause significant damage to the ceramics. The high costs of these ceramic machining techniques force designers to accept the lower performance and higher life cycle costs of metal components in order to meet cost requirements. For example, for one set of specified CMC engine components contact machining is currently employed. Their through hole features require the use of two costly tools for every 4 holes. In production more than 56,000 such features will be machined per year. Contact tool cost is approximately $400 per hole. Use of the PSI Laser Machining Center will eliminate this excessive tool wear, yielding for this one set of specified engine components a savings of $22.4M per year in tool cost alone at full rate production for this platform. The PSI Laser Machining Center enables a dramatic decrease in ceramic manufacturing costs so that designers can take full advantage of the benefits ceramics and CMCs offer over metal components. These advantages include increased durability, higher temperature operation, longer lifetimes, significantly decreased life cycle cost, and lighter weight. The PSI Laser Machining Center thus eliminates the traditional production costs of complex shape ceramic components so that they will be cost competitive with their metal counterparts.
TECHNOLOGY DESCRIPTION The PSI laser machining technology employs a highly controlled intense laser cutting head integrated in a multi-axis Computer Numerical Control (CNC) machining base. Laser intensity and part motion are synchronized to rapidly machine features of interest using operations that include precision cutting, drilling, beveling and countersinking. Our precision laser machine process minimizes damage to machined parts and eliminates the need to replace machining tools. The PSI laser machining center is a dry process as opposed to a wet process, thus eliminating many manufacturing steps. The PSI ceramic laser machining process is substantially faster and less costly than the Page 2 of 5 Physical Sciences Inc. NAVAIR Public Release 08-1234 Distribution: Statement A - "Approved for public release; distribution unlimited"
current process. For a specific component type, we have demonstrated a 25 fold decrease in machining time. As described above, the savings in tool acquisition cost are significant, resulting in greater than a 10 fold decrease in machining costs These savings will accrue on ceramic propulsion components that are baselined on a current Navy platform. The PSI Laser Machining Center is cost competitive with existing mill and waterjet CNC systems and offers dramatically improved ability to machine ceramics and CMC. For example, Figure 1 shows two typical features we have machined to required tolerance, and the features, advantages, and benefits of PSI’s laser machining center are shown in Table 1.
Figure 1. PSI laser machined CMC features and aircraft cut-out Table 1: Features, Advantages, and Benefits Features Tool Use
Advantages No high cost disposabletooling Significantly faster thantraditional machiningmethods Coolant free process
Benefits Dramatic production costsavings Greatly reducedmanufacturing cycle time No risk of material degradationReduced manufacturingcycle time Increased machine tool life
Machining Tolerance
Reduction of powdered andabrasive waste Better rough cut tolerance
Work Piece Fixturing
Reduced fixture complexity
Reduced machining setuptime Reduced fixturing cost
Machining Rate
Coolant Usage
Material Removed
Reduced final machiningtime
Page 3 of 5 Physical Sciences Inc. NAVAIR Public Release 08-1234 Distribution: Statement A - "Approved for public release; distribution unlimited"
CURRENT STATE OF DEVELOPMENT During the Phase II STTR, PSI has successfully integrated a fiber optic delivered laser with a typical CNC and demonstrated the ability to rapidly machine features of interest to required tolerances. We have specified a laser machine center that will be installed in a manufacturing line. System components are being ordered. During the Phase II option, scheduled to begin in December 2008, we will complete integration of this machine at PSI. We plan to complete the subsequent installation and shakedown of the CNC laser machine center in the manufacturing line by July of 2009. We have machined test specimens that will demonstrate no mechanical or environmental strength or lifetime knock-downs in comparison to specimens machined using the traditional methods. A formal test program is underway, and initial results are promising. We will machine additional qualification specimens under program office funding in the winter of 2008/2009 using the laser that will be installed in the manufacturing line. These qualification components will be tested in the Spring of 2009. We continue to develop machining conditions and specifications for the features of interest with machining rates in excess of 50 inches/minute. The technology is currently at TRL of 5. Table 2 shows technology development milestones. Table 2. PSI Laser Machining Center Development Milestones Milestone Subprototype Demonstrated Demonstrate that machined material is not degraded by the laser machining process Phase II Option Begin Machine and test qualification panels under SPO funding PSI Laser Machine Tool Delivery and Demonstration PSI Ceramic Laser Machining Documentation/Training PSI Laser Machine Center qualified during LRIP
TRL Risk Measure of Success 5 Low Demonstrated machined features in CMC at specified tolerances 5 Low Customer acceptance of mechanical properties Preliminary data indicates no degradation
TRL Date 7/30/2008 10/31/2008
12/1/2008 3/1/2009
5
Low Customer acceptance of mechanical properties
6
Mod Successful component machining erate (meeting customer specifications)
07/15/2009
7
Low Delivery of Documents
12/31/2009
7
Low Independent operation by customer 2/15/2010
Page 4 of 5 Physical Sciences Inc. NAVAIR Public Release 08-1234 Distribution: Statement A - "Approved for public release; distribution unlimited"
PSI is currently providing ceramic and CMC machining services. In addition we will work with specific customers to develop laser machining processes for their specific applications, adapting the PSI Laser Machining Center for their specific requirements. Currently, we are seeking program office and/or commercial support for the adaptation and qualification of the PSI laser machining processes for additional ceramic component applications on a range of DoD platforms. PSI laser machining will be cost enabling for components that include: • • • • •
additional aircraft engine and air frame ceramic components ceramic armor rocket and hypersonic propulsion components advanced aerospace structures value added machining of ceramic net shape processed components
REFERENCES Please coordinate all contacts with the Technical Point of Contact (TPOC). • • •
TPOC, 301-342-9343 TPOC, 301-342-9355 Terry Brady, ABL/ATK [email protected]
ABOUT THE COMPANY Physical Sciences Inc (PSI) is a 35 year old, $40M/year employee owned company whose objective is to bridge the gap between the federal government and prime contractors in the research, development and deployment of technology. Our focus is to provide contract research and development services in a variety of technical areas to both government and commercial customers. PSI’s sustainable competitive advantage lies in its ability to undertake product development through manufacturing prototype and ultimately transition it to the military and commercial market sectors through direct sales and marketing strategic partnerships, pilot scale manufacturing, and licensing our proprietary products and systems. PSI will supply laser-machining centers to manufacturers of ceramic components and they are available for purchase. In addition, PSI intends to operate a laser-machining center for both toll machining and machining process development services. Capital for the facility will be raised internally by PSI. This approach leverages the strengths of PSI to develop new technology while enabling our partners to quickly utilize these new abilities in their existing manufacturing environments.
Page 5 of 5 Physical Sciences Inc. NAVAIR Public Release 08-1234 Distribution: Statement A - "Approved for public release; distribution unlimited"
Contact: Dr. Mark Druy Phone: (978) 738-8195 Email: [email protected] Website: http://www.psicorp.com Command: NAVAIR Topic: N06-T012
PROBLEM STATEMENT Aircraft engine and exhaust washed structures require highly efficient ceramic matrix composite (CMC) designs to minimize weight and withstand severe environmental conditions. It is time consuming and expensive to fabricate these components, as they require significant post-fabrication machining to precise dimensions. The machining process is very difficult, due to the low thermal conductivity and hard, brittle, abrasive nature of CMCs. As a result of the unique characteristics of CMCs, existing methods of machining and drilling are inefficient and expensive. Machine tools are easily damaged and require frequent replacement due to over-heating and repeated contact with the hard and abrasive material. In addition, the CMC components are prone to damage from improper machining. A high-speed machining process is needed to eliminate many of the major cost and risk impediments for transitioning these materials to aircraft production. PSI is addressing this need by developing a highly innovative high speed laser machining center. The PSI laser machine center is demonstrating machining of CMC components at rates 25 times faster and 1/10 the cost of the original baseline machining techniques. These improvements are cost and time enabling for production of CMC aircraft components. Our technology is currently being qualified in the manufacturing line for a specific Navy platform. The JSF program office is intimately involved with this qualification process.
WHO CAN BENEFIT? Immediate applications for the PSI Laser Machining Center are CMC engine components for JSF and other CMC components for other aircraft platforms. In addition, all systems that want to take advantage of the higher performance, lighter weight and reduced life cycle costs achieved by use of machined CMC and ceramic components will benefit from this Page 1 of 5 Physical Sciences Inc. NAVAIR Public Release 08-1234 Distribution: Statement A - "Approved for public release; distribution unlimited"
technology. This PSI machining technology can be expanded to machine not only additional aircraft components, but also rapid machining of other ceramic materials. Immediate applications are: • • • •
ceramic armor rocket and hypersonic propulsion components advanced aerospace structures value added machining of ceramic net shape processed components
BASELINE TECHNOLOGY The baseline machining technology for ceramic materials is water jet rough cutting or contact machining (milling). Both operations are used at different times, not necessarily in combination. In either operation the components are submerged in coolant, requiring costly and time consuming subsequent cleaning and drying operations. These conventional machining techniques can cause significant damage to the ceramics. The high costs of these ceramic machining techniques force designers to accept the lower performance and higher life cycle costs of metal components in order to meet cost requirements. For example, for one set of specified CMC engine components contact machining is currently employed. Their through hole features require the use of two costly tools for every 4 holes. In production more than 56,000 such features will be machined per year. Contact tool cost is approximately $400 per hole. Use of the PSI Laser Machining Center will eliminate this excessive tool wear, yielding for this one set of specified engine components a savings of $22.4M per year in tool cost alone at full rate production for this platform. The PSI Laser Machining Center enables a dramatic decrease in ceramic manufacturing costs so that designers can take full advantage of the benefits ceramics and CMCs offer over metal components. These advantages include increased durability, higher temperature operation, longer lifetimes, significantly decreased life cycle cost, and lighter weight. The PSI Laser Machining Center thus eliminates the traditional production costs of complex shape ceramic components so that they will be cost competitive with their metal counterparts.
TECHNOLOGY DESCRIPTION The PSI laser machining technology employs a highly controlled intense laser cutting head integrated in a multi-axis Computer Numerical Control (CNC) machining base. Laser intensity and part motion are synchronized to rapidly machine features of interest using operations that include precision cutting, drilling, beveling and countersinking. Our precision laser machine process minimizes damage to machined parts and eliminates the need to replace machining tools. The PSI laser machining center is a dry process as opposed to a wet process, thus eliminating many manufacturing steps. The PSI ceramic laser machining process is substantially faster and less costly than the Page 2 of 5 Physical Sciences Inc. NAVAIR Public Release 08-1234 Distribution: Statement A - "Approved for public release; distribution unlimited"
current process. For a specific component type, we have demonstrated a 25 fold decrease in machining time. As described above, the savings in tool acquisition cost are significant, resulting in greater than a 10 fold decrease in machining costs These savings will accrue on ceramic propulsion components that are baselined on a current Navy platform. The PSI Laser Machining Center is cost competitive with existing mill and waterjet CNC systems and offers dramatically improved ability to machine ceramics and CMC. For example, Figure 1 shows two typical features we have machined to required tolerance, and the features, advantages, and benefits of PSI’s laser machining center are shown in Table 1.
Figure 1. PSI laser machined CMC features and aircraft cut-out Table 1: Features, Advantages, and Benefits Features Tool Use
Advantages No high cost disposabletooling Significantly faster thantraditional machiningmethods Coolant free process
Benefits Dramatic production costsavings Greatly reducedmanufacturing cycle time No risk of material degradationReduced manufacturingcycle time Increased machine tool life
Machining Tolerance
Reduction of powdered andabrasive waste Better rough cut tolerance
Work Piece Fixturing
Reduced fixture complexity
Reduced machining setuptime Reduced fixturing cost
Machining Rate
Coolant Usage
Material Removed
Reduced final machiningtime
Page 3 of 5 Physical Sciences Inc. NAVAIR Public Release 08-1234 Distribution: Statement A - "Approved for public release; distribution unlimited"
CURRENT STATE OF DEVELOPMENT During the Phase II STTR, PSI has successfully integrated a fiber optic delivered laser with a typical CNC and demonstrated the ability to rapidly machine features of interest to required tolerances. We have specified a laser machine center that will be installed in a manufacturing line. System components are being ordered. During the Phase II option, scheduled to begin in December 2008, we will complete integration of this machine at PSI. We plan to complete the subsequent installation and shakedown of the CNC laser machine center in the manufacturing line by July of 2009. We have machined test specimens that will demonstrate no mechanical or environmental strength or lifetime knock-downs in comparison to specimens machined using the traditional methods. A formal test program is underway, and initial results are promising. We will machine additional qualification specimens under program office funding in the winter of 2008/2009 using the laser that will be installed in the manufacturing line. These qualification components will be tested in the Spring of 2009. We continue to develop machining conditions and specifications for the features of interest with machining rates in excess of 50 inches/minute. The technology is currently at TRL of 5. Table 2 shows technology development milestones. Table 2. PSI Laser Machining Center Development Milestones Milestone Subprototype Demonstrated Demonstrate that machined material is not degraded by the laser machining process Phase II Option Begin Machine and test qualification panels under SPO funding PSI Laser Machine Tool Delivery and Demonstration PSI Ceramic Laser Machining Documentation/Training PSI Laser Machine Center qualified during LRIP
TRL Risk Measure of Success 5 Low Demonstrated machined features in CMC at specified tolerances 5 Low Customer acceptance of mechanical properties Preliminary data indicates no degradation
TRL Date 7/30/2008 10/31/2008
12/1/2008 3/1/2009
5
Low Customer acceptance of mechanical properties
6
Mod Successful component machining erate (meeting customer specifications)
07/15/2009
7
Low Delivery of Documents
12/31/2009
7
Low Independent operation by customer 2/15/2010
Page 4 of 5 Physical Sciences Inc. NAVAIR Public Release 08-1234 Distribution: Statement A - "Approved for public release; distribution unlimited"
PSI is currently providing ceramic and CMC machining services. In addition we will work with specific customers to develop laser machining processes for their specific applications, adapting the PSI Laser Machining Center for their specific requirements. Currently, we are seeking program office and/or commercial support for the adaptation and qualification of the PSI laser machining processes for additional ceramic component applications on a range of DoD platforms. PSI laser machining will be cost enabling for components that include: • • • • •
additional aircraft engine and air frame ceramic components ceramic armor rocket and hypersonic propulsion components advanced aerospace structures value added machining of ceramic net shape processed components
REFERENCES Please coordinate all contacts with the Technical Point of Contact (TPOC). • • •
TPOC, 301-342-9343 TPOC, 301-342-9355 Terry Brady, ABL/ATK [email protected]
ABOUT THE COMPANY Physical Sciences Inc (PSI) is a 35 year old, $40M/year employee owned company whose objective is to bridge the gap between the federal government and prime contractors in the research, development and deployment of technology. Our focus is to provide contract research and development services in a variety of technical areas to both government and commercial customers. PSI’s sustainable competitive advantage lies in its ability to undertake product development through manufacturing prototype and ultimately transition it to the military and commercial market sectors through direct sales and marketing strategic partnerships, pilot scale manufacturing, and licensing our proprietary products and systems. PSI will supply laser-machining centers to manufacturers of ceramic components and they are available for purchase. In addition, PSI intends to operate a laser-machining center for both toll machining and machining process development services. Capital for the facility will be raised internally by PSI. This approach leverages the strengths of PSI to develop new technology while enabling our partners to quickly utilize these new abilities in their existing manufacturing environments.
Page 5 of 5 Physical Sciences Inc. NAVAIR Public Release 08-1234 Distribution: Statement A - "Approved for public release; distribution unlimited"
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