MTC Handbook Scenarios 1 & 3

6. How can technology help?

6b. Review existing products

Summary approach

The first step is to review the existing product designs and check materials currently
being used and materials available. This allows an initial downselection of parts for the
feasibility study.

Optimisation options are then considered and a decision made as to whether the
use of AM is justified. This will involve consideration of several factors including
component sizes, build orientation and build quantities required.

Review Check Understand Decide if Evaluate
current design feasibility and evaluate there is a software and
AM material cost benefit skills required

properties

The proposed AM material properties need to be thoroughly understood and
evaluated in order for a robust cost benefit analysis to be carried out. Will using AM
for the selected components deliver additional margin to the business? If yes, the
business needs to assess the design implications.

Since AM requires a different design approach to conventional manufacturing
techniques, the appropriate design software needs to be selected and design skill
gaps in the business determined.

Benefits

Conducting a robust feasibility study, supported by independent expertise, allows a
business to determine if AM can improve returns from its product range. It informs the
decision of whether to take advantage of the benefits of this emerging technology by
providing;

  an understanding of how AM can increase efficiency
  an understanding of the AM cost model
  information on how to improve existing products
  a detailed description of the AM process
  software and training recommendations

See also: 6c.4
Design for additive manufacturing – capability demonstration 6d.5
Options for post processing additive layer parts 9a.6
Design for additive manufacture – skill transfer

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6b.2 Feasibility for net shape manufacturing
Net shape (NS) processes are among the fastest growing metal forming
technologies. They provide an efficient use of materials and vastly increased
design freedom.

Drivers
NS has proven to be more efficient than most conventional subtractive
manufacturing processes. It can provide a lean solution, with high levels of precision
and reduced machining times and costs. However, conducting feasibility studies
before investing in this technology is crucial to ensure that NS can be applied to any
given component.
Conducting a feasibility study, supported by an independent expert partner, will
determine whether these technologies can be applied to existing components by;
  de-risking the decision process
  analysing if and how NS can be applied to the component
  understanding the benefits of all NS processes
  identifying the most suitable NS process

Fig 6b.2.1: Example of a component produced by metal injection moulding (MIM) Page 151
6. How can technology help?

6. How can technology help?

6b. Review existing products

Summary approach

Firstly, a baseline needs to be established by analysing the current product range and
current manufacturing processes. The most inefficient areas of the current process in
terms of machining time, material waste or other factors are identified. An evaluation
is made of which, if any, of these inefficiencies in the current process can be improved
through NS manufacturing.

All available NS processes need to be considered to ensure the most appropriate
process is selected. Working with an expert, independent partner ensures this is
done robustly.

Examine Determine Identify Explain where Recommend
current inefficient suitable NS NS can help new process
processess techniques
areas

A cost benefit analysis of where and how the most appropriate NS process can add
the most value to business is then developed.

Benefits

Conducting a robust feasibility study, supported by independent expertise, allows a
business to determine if NS can improve returns from its product range. It informs the
decision of whether to take advantage of the benefits of this emerging technology
by providing;
  information on how to improve existing processes
  an understanding of how NS can increase efficiency
  independent and impartial equipment recommendations
  a detailed description of the new process

See also: 6c.2
Demonstrate net shape equipment and process 6c.3
Design for net shape – capability demonstration 9a.5
Design for net shape – skill transfer

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6b. Review existing products

6b.3 Feasibility study-problem solution generation
Problems in manufacturing a current or new product or component, cost-
effectively, consistently and to the satisfaction of the customer, need to be
addressed in a systematic and creative way. Working with an experienced partner
brings robustness to initial root cause analysis and ensures all options, including
new technology options, are considered when generating potential solutions.

Drivers
The generation of solutions must be preceded by identification of the root causes of
a problem. Often the source and nature of the problem sits beneath the initial visible
symptoms. Working with an impartial, independent partner can avoid the in-house
team wrongly assuming they already know the cause.
Once the root causes of a problem are known, a business can identify potential
solutions. Working with an impartial partner will bring additional options –
including new technology options – to this process. It is important that options are
rigorously examined and systematically evaluated. Again, a partner experienced in
downselection techniques reduces the risk of settling for the first rather than the best
solution. In short, the benefits from this approach include;
  the true root causes of the problem are identified
  solutions offering the most value to the business are identified

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6b. Review existing products

Summary approach

It is recommended a business involves employees who work in the relevant
manufacturing areas at all stages of root cause analysis and solution generation.
This is crucial to understanding fully the issues.

See also: 8.2
Embedding use of practical problem solving tools
Some commonly used problem solving tools are described in Fig 8.2.2

A robust root cause analysis needs to consider;

  Is the current manufacturing process optimised? The business can achieve
the required result with existing resources if it improves the way these are
used and deployed.

 Is the current component design optimised? The business can achieve the required
result with existing resources if the component is redesigned to allow effective use
and deployment of those resources.

  Is the current manufacturing process capable? Even if the business uses existing
resources in the best possible way, it still may not achieve the required result.
It needs to develop or invest in a capable process.

The first step is to define clearly the problem to be explored. What is in scope and
what is out of scope? Brainstorm the contributing causes. Analyse and group these
using 5Ys, or a similar tool, to cluster causes with a common root. Capture these in a
fishbone diagram, or similar analysis tool. The grouped root causes are then ranked in
order of impact on the product, component or current process.

Define Brainstorm Analyse Generate Evaluate and
and group root cause solutions prioritise

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6b. Review existing products

Once the issues are identified and understood, potential solutions can be generated
to address the highest ranked root causes. Potential solutions identified may point to
one or more of;

  A need to optimise the current process
In this case, see value accelerators in;

Chapter 7  Levering benefit from technology
Chapter 8  Levering benefit from operational efficiency

  A need to optimise the product or component design
In this case, see value accelerators in;

Chapter 9a  Design for process
Chapter 9b  Problem solving tools – pre-production

  A need to identify and develop a capable manufacturing process
In this case, see value accelerators in;

Chapter 6a Review existing operations.
Is there potential for technology improvement?

Chapter 6c  Trial alternative technology
Chapter 6d Manufacturing problems and opportunities.

How can technology help?

The potential solutions are then ranked, using a prioritisation grid, or similar tool.
 Which solutions are feasible? Short term, medium to long term?
 Considerations here include; the resources of the business, their readiness to

absorb technological or process change, and the degree of risk associated with
any suggested technology solutions
 Of the feasible solutions – which will contribute most value to the business?
Short term, medium to long term?
This requires a first pass at cost benefit analysis. Any quick wins identified are
implemented and longer term improvement plans agreed.

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6b. Review existing products

Benefits

A systematic approach to root cause analysis and problem solution generation, with
support from an expert, impartial partner, can;
  identify all root causes of an identified problem
  identify opportunities to streamline existing processes
  identify opportunities to improve productivity and reduce costs
  identify range of solution options – including appropriate technology options
  identify solution that will deliver maximum business benefit

“ H ere at Dearman, we are developing cutting-edge clean cold and power
technologies for a range of applications across transport, logistics and
the built environment. As a partner in Dearman’s liquid air heat hybrid
project, the MTC’s virtual reality suite has been valuable in considering the
packaging and assembly operations. With the application destined for a
bus initially, making the system compact is vitally important to preserve
space for passengers. The heat hybrid system will improve the efficiency
of heavy duty vehicle’s propulsion engine, reducing fuel consumption and
emissions while also providing auxiliary power for electrical processes
and cooling for passengers. As an SME, it’s also been key to work with the
MTC to consider how best to reduce the cost of system components.
As Dearman technology matures at an ever greater pace, and the heat
hybrid project progresses to on-vehicle testing, we look forward to
”working the MTC further on future projects.
Michael Ayres, Deputy Chief Executive, Dearman

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6b. Review existing products

6b.4 Prediction of weld quality
Fusion welding processes and shaped metal deposition (or cladding) often
induce substantial residual stresses and unwanted distortion. Simulation of the
thermo-mechanics of welding is now mature enough to predict accurately these
critical quality factors.

Drivers
Traditionally, welding or cladding of new components needs to be developed
from lengthy – and so costly – trials with a skilled operator. With finite element (FE)
methods, which have already been validated against existing processes, it is much
quicker to demonstrate that stresses and distortions are at an acceptable level. This
can dramatically reduce the number and cost of trials needed. A business will benefit
from FE tools to predict weld quality where;
 lengthy trials are usually needed to demonstrate a method
 welds may be the weak point of the product or component
 understanding the strength of the join is critical to safety
 the strength of the join affects the usable life of the product
 simulation is accurate enough to predict problems

Fig 6b.4.1: Welding showing stress cracking. Image courtesy of The Welding Institute

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6b. Review existing products

Summary approach

The first step is to define the welding or cladding process, the type of heat source
model to be used and the speed and power input. Generate an FE model of the
component for analysis using specialised codes. Support from an expert partner
will be needed if the in-house team are not experienced in codes suitable for
FE modelling.

Define the Create finite Optimise Evaluate Present
process element model the model distortions conclusions
and stresses on optimal
processes

Optimise the model to produce a prediction of stresses and distortions. Setup a
parameter study to understand the effects of process variants and resolve the model
multiple times. Produce summary plots showing how aspects critical to quality
depend on both welding parameters and the tool path.

Fig 6b.4.2: A finite element analysis showing predicted stresses

From this, recommendations can be made on the optimal welding or cladding
process and any risks can be highlighted.

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6b. Review existing products

Benefits

The use of FE tools, with external support from a partner skilled in their application,
removes the need for time consuming and costly prototyping. This saves design and
production time and material, reducing costs. Fewer design iterations before concept
validation means reduced time to market. Effective use of FE tools can;

 reduce the number of physical trials needed
 predict if the final part will meet manufacturing tolerances
 highlight areas where stresses are concentrating
 understand the effect of the welding speed and power input
 optimise the welding tool-path

See also: 5c.4
Discovering value from simulation tools 6d.2
‘Weldability’studies for new material combinations 6d.3
Options for joining complex geometrical features 6e.3
Rapid metal deposition – capability demonstration 9b.3
Reducing stress points within component design

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Page 160

Chapter 6c

Trial alternative technology

Introduction
 6c.1 Machine trials
 6c.2 Demonstrate net shape equipment and
process
 6c.3 Design for net shape – capability
demonstration
 6c.4 Design for additive manufacturing –
capability demonstration

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6. How can technology help?

6c. Trial alternative technology

Introduction
To remain competitive a business must engage with advances in manufacturing
technology. However, investment is costly and carries significant risk. Any investment
decision regarding which technologies to use in the business or supply chain
requires a thorough understanding of the benefits and challenges that the
technology can bring.
Trialling new technology is a way to assess how it will perform in an operational
environment and how it can provide a competitive advantage to the business.

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6c. Trial alternative technology

6c.1 Machine trials
[For the purposes of this value accelerator a variety of laser technologies are used as
examples. The principles behind carrying out a machine trial are the same for any
technology. An indicative list of the technologies within the experience and expertise of
the MTC is given in; 5a.2 Key questions for your technology vendor]
Advances in laser technology allow the use of disruptive methods of machining
small components, adding surface functionality and cleaning parts.
Lasers have become more powerful and cheaper, and more efficient delivery
systems have been developed. As a result new processes such as laser
micromachining, texturing and cleaning, have emerged.
Laser based machine trials – in effect trialling before you buy – de-risks the decision
to invest in this technology. Carrying out these trials with an experienced partner
other than a potential vendor offers an independent assessment of likely benefits.

Drivers
Laser micromachining;
Machining hard, brittle materials is expensive. It increases tooling costs and
enables quality issues, such as dimensional instability or burr, to be overcome.
Laser micromachining is a flexible machining process offering an alternative to
conventional machining processes. Laser micromachining can;
 cut complex shapes without the restrictions of tooling
 combine multiple manufacturing methods into one
 improve productivity
 produce miniaturised components, so increasing capability
 process almost any material, also increasing capability

Fig 6c.1.1: Parts machined using laser micromachining technology

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6c. Trial alternative technology

Laser texturing;
Increased global competition has driven many industry sectors to improve product
performance by providing dedicated functionalities. These might include tailored
friction, or antibacterial or self-cleaning properties. Laser texturing is a quick,
repeatable, clean and material independent process to achieve such surface
properties and functionality. Laser texturing can;
 improve the performance of products by adding functionality
 increase material flexibility
 increase process speed
 reduce process steps
 increase repeatability
 give consistent quality on each application
 increase productivity compared to conventional techniques

Fig 6c.1.2: Microscopic picture of a surface subjected to laser texturing

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6c. Trial alternative technology

Laser cleaning;
Advanced materials, high performance coatings and increasing restrictions on the use
of chemical cleaning methods (REACH – EU regulations) including chemical etching,
drives the need for new methods. Laser cleaning can;

o  ffer a cost effective alternative cleaning method
 d evelop constant quality on each application
 c lean without affecting the integrity of the substrate
o  ffer an environmentally friendly cleaning method
 s horten set up times
 i ncrease productivity

Fig 6c.1.3: Part being cleaned using laser cleaning technology (before and after)

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6c. Trial alternative technology

Summary approach

The approach for trialling these technologies, or indeed trialling any new technology,
starts with data capture. Identify the specification and expected performance of the
technology to be trialled and capture all business requirements from, and objectives
for, the technology.

Then conduct trials to identify the actual achievable process parameters. This is an
iterative process with a range of parameter settings trialled in a series of designed
experiments. This allows the process to be optimised.

Collect Conduct Optimise Evaluate Recommend

Evaluate the results from the experiments. Does the optimised performance meet the
business requirements? Is the trialled technology better, quicker, or cheaper – or all
three – than the alternative? The business can then arrive at an informed technology
investment decision, or know what further information is required.

Benefits

Machine trials of any technology de-risk the investment decision and de-risk the
future use of that technology. Properly conducted and evaluated they will;

 enable (some) technology optimisation before adoption
 identify technology challenges up front
 enable more robust risk identification and management
 inform investment decisions
 generate confidence in investors or stakeholders
 underpin a robust business case

See also: 5a.2
Key questions for your technology vendor 5b.1
Feasibility study for new technology investment

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6c. Trial alternative technology

6.c.2 Demonstrate net shape equipment and process
The term net shape (NS) encompasses three individual processes; hot isostatic
pressing (HIP), cold isostatic pressing (CIP) and metal injection moulding (MIM).
NS equipment represents a big investment for any business. It is vital to
understand its capabilities before taking the business decision. By seeking practical
demonstrations from non-vendors, a business increases its knowledge of the
technology in a non-biased fashion. This de-risks the investment decision.

Drivers
Net shape is one of the fastest growing metal forming technologies. It provides
an efficient use of materials and vastly increased design freedom. Understanding
how this technology can be applied to the manufacturing process is essential
to assessing if an investment should be made or not. Net shape equipment and
processes can offer;
 more efficient use of material
 less waste than subtractive processes
 improved material properties
 shorter lead times
 increased productivity

Fig 6c.2.1: Part being manufactured using a net shape manufacturing process (HIP)

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6c. Trial alternative technology

Summary approach

First, the business needs and objectives are captured. What benefit or additional
capability does the business want from NS? The capabilities and limitations of
alternative NS technologies can then be evaluated and matched against the business
needs in an unbiased manner.

Evaluate Learn Experience Perform Gain

For downselected technologies, a demonstration allows the business to learn
about net shape equipment, processes, applications, benefits and limitations. This is
achieved through hands on practical experience.

A demonstration lets the business perform real world activities using net shape
technologies and gain practical understanding of the capabilities and limitations.

Benefits

Demonstrations of net shape equipment and processes provide a business with
first-hand experience and understanding of how this technology can have a positive
impact on a business. Demonstrations can;
 de-risk the decision to invest in NS technology
 offer understanding of which type of NS is most suitable
 demonstrate the benefits NS can bring to a business
 offer understanding of the limitations of NS
 underpin a robust business case

See also: 5a.2
Key questions for your technology vendor 5b.1
Feasibility study for new technology investment 6b.2
Feasibility study for net shape manufacture 6e.3
Rapid metal deposition – capability demonstration

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6c. Trial alternative technology

6c.3 Design for net shape – capability demonstration
As explained earlier in this guide, the term net shape (NS) encompasses three
individual processes; hot isostatic pressing (HIP), cold isostatic pressing (CIP) and
metal injection moulding (MIM). NS manufacturing has many benefits compared
to the conventional processes of casting, forging and machining from solid
material. One advantage is the ability to produce high performance components
with minimal material waste.

Drivers

Many factors come into play when designing for NS processes. Independent advice
and a capability demonstration from experts will help a business understand these.
It helps answer the preliminary question: is NS right for this part? If NS is a feasible
option, independent advice and demonstrations help a business develop highly
efficient component and tooling designs. NS processes can;
 produce parts with non-forgeable or non-machinable features
 decrease the number of component parts or joints
 increase standardisation

Summary approach

The final design process for NS will vary according to which manufacturing method
is to be used.

The first step is to identify which parts are suitable for NS and select the most
appropriate NS process. There is likely to be some modification of parts to fit the
selected manufacturing process.

Identify Select Modify Design Produce

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6c. Trial alternative technology

Tooling is then designed using low cost manufacturing techniques based on the
desired geometry. Next CAD models are produced and drawings engineered.
The final step is to produce a full drawing pack for manufacture.

Fig 6c.3.1: Simplified geometry of a valve section

Benefits

Independent advice and demonstrations of design for net shape capability enable
a business to assess the end-to-end capability of NS processes. They will identify the
parts for which NS is suitable and the benefits of its use. It allows a business to;

 design more efficiently
 design forms that make maximum use of the process
 increase metrology and non-destructive testing efficiency
 decrease the amount of post process machining required
 reduce total production cost

See also: 6b.2
Feasibility study for net shape manufacture 9a.5
Design for net shape – skill transfer

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6c. Trial alternative technology

6c.4 Design for additive manufacturing – capability demonstrations
Additive manufacturing (sometimes colloquially referred to as 3D printing)
emerged as a way to manufacture intricate and complex parts without the
need for machining and assembly.

Fig 6c.4.1: Example of a lattice structure made with an additive manufactuing process

Drivers

Additive manufacturing (AM) is still a relatively new process. However it provides
many advantages when compared to more traditional manufacturing techniques.
Design for AM requires a different approach than design for conventional methods.
For example, it is possible to use lattice structures or designs which mimic nature.
This, in turn, allows a business to make more efficient products.

Without an appropriate design process, the use of AM cannot reach its full potential
and may be wrongly dismissed as not cost effective. Independent advice and a
capability demonstration from experts enables a business to develop better products
cost effectively and manufacture components that otherwise would be unfeasible.
It helps a business;
 understand the AM process and design for process rules
 choose the right software tools
 understand the cost models
 understand impact of design decisions on part performance

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6c. Trial alternative technology

Fig 6c.4.2: Complex geometrical component, demonstrating the potential of additive manufacturing

Summary approach
The first step is to identify if a part is suitable for AM and select the most appropriate
AM process. Then define the product specifications and the requirements of
the business. What is the business hoping to achieve by using AM rather than
conventional processes? The next step is ideas generation and the development of
concepts. These concept designs can be analysed to downselect the best solution(s).

Define Generate Optimise Modify Produce

After optimisation to achieve the best result, the chosen design is used to
manufacture a physical sample of the part. This can be inspected against the
specification, and the design modified if required. The design process will also cover
identifying and optimising any post AM processing required on the part.

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Benefits

Independent advice and use of a capability demonstration for design for AM enables
the business to extract the maximum value from the AM process. They allow a
business to;
 make the correct choice of software tools
 understand AM process and design rules
 maximise efficiency in material use
 minimise post process costs
 achieve the best design for functionality

“ Working with the MTC, we can better explore design, processing and
fabrication options. This highlights the major challenges to the creation of
complex components through selective laser melting systems – letting us
”resolve issues before production.
Sarat Babu, Director, Betatype

Betatype specialises in developing unique and highly complex products
through the design of bespoke materials

See also: 6b.1
Feasibility study for additive manufacture 9a.6
Design for additive manufacture – skill transfer 6e.3
Rapid metal deposition – capability demonstration

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Chapter 6d

Manufacturing problems
and opportunities

Introduction
 6d.1 Prototyping and testing of
advanced tools and fixtures
 6d.2 Weldability studies for new
material combinations
 6d.3 Options for joining complex
geometrical features
 6d.4 Options for machining with high
temperature alloys
 6d.5 Options for post-processing
additive layer parts

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6d. Manufacturing problems and opportunities

Introduction
The value accelerators within this chapter give examples of how technology can help
with a variety of manufacturing challenges.
The examples chosen represent only a sample of the problems and opportunities a
business might choose to address with new technology.
The solutions suggested are selected from the latest studies and technologies
developed across the fields of high integrity fabrication, advanced tooling and
fixturing, and non-conventional machining.
Again, these are example technologies only.

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6d. Manufacturing problems and opportunities

6d.1 Prototyping and testing of advanced tools and fixtures
The development and integration of advanced tooling or fixturing within an
existing manufacturing process, or ahead of an upcoming process, presents a
challenge. Deployment of improved tooling to an existing process can interrupt
production. Delays to the tooling and fixturing readiness for a new process
can slow time to market. Smoothing the adoption process is key to minimising
disruption or delay to the customer

Drivers
The need for proven tools and fixtures ahead of a production run is self-apparent.
Achieving manufacturing readiness without disruption or delay will save both time
and costs. However, if the business wants the benefits that advanced tooling and
fixturing can offer – e.g. integration of telemetry equipment – their adoption can be
de-risked. Seeking independent expert advice and support on effective prototyping
and testing ahead of the production run can;
 provide an overview of technology-for-design validation
 identify potential for productivity and efficiency improvements
 provide an impartial overview of latest tooling and fixturing
 evaluate fixture suitability, with a quick build demonstration

Fig 6d.1.1: Component demonstrating typical additive features that are difficult to finish or post
process in an automated and controlled way

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6d. Manufacturing problems and opportunities

Summary approach

The first step is to review the current design of tooling and fixtures within the
business. What are the current capabilities and constraints? Identify the weaknesses
of the current design. Then fully capture the business requirements. What is the
business objective in adopting an advanced tooling or fixturing solution?

Appraise Research Design and Manufacture Test and
options simulate validate

The options currently available are researched and an initial downselection
made. Solutions are then designed and developed based on the business needs.
Manufacturing simulation tools and techniques are used to verify the potential
solutions in a virtual environment. A physical prototype of the best solution can
then be manufactured and tested. This is validated against the original brief and
adjusted if required.

Benefits

A key benefit is the reduction in lead time for the deployment of new equipment
and techniques. Effective prototyping and testing of advanced tooling and fixturing
ahead of production ensures a right first time design solution. Benefits include;
 right first time, saving design and prototyping costs
 reduced lead time from project start to successful adoption
 quicker time to market for new products
 avoidance of disruption to customers
 less risk of interruption to production

See also: 5b.2
Adaptive, fast make, lightweight fixtures–feasibility study 7b.1
Changeover reduction via ATF 7b.2
Smart tooling and fixturing

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6d. Manufacturing problems and opportunities

6d.2 Weldability studies for new material combinations
Many businesses need to work with new and exotic materials to retain or increase
competitiveness in the modern manufacturing arena. To do so successfully, the
business needs to explore the best methods of joining new materials, new material
combinations and dissimilar material combinations. Optimising the joining process
can offer a significant cost advantage and improve component performance.

Drivers
There is a market demand for components using new and exotic materials or
innovative material combinations. Legislative changes to production standards and
practices can also prompt the need for change to materials or improvement to the
joining process. Seeking independent expert support when carrying out a weldability
study can;
 provide an overview of technological capabilities
 identify potential for productivity and efficiency improvements
 provide an impartial overview of welding methods
 identify options for new materials and new combinations
 access state of the art technology for research and production
 access in-depth expertise in materials and welding processes

Fig 6d.2.1: Laser welding Page 180
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6d. Manufacturing problems and opportunities

Summary approach

Thorough assessment of the business need is the essential first step towards
addressing any technological issue. Next, experts in the field should be consulted.
These may be universities, industrial partners or potential suppliers. This will allow
initial potential solutions to be downselected against the business requirements.

Capture Consult Evaluate Perform Analyse and
requirements experts weld trials recommend

An experiment of structured welding trials can then be designed and conducted to
test solutions. Identifying potential providers of a manufacturing joining solution is
an essential element of this study. Results are analysed and the best available solution
recommended.

Benefits

A significant competitive lead is gained from understanding advanced joining
processes. It can give a business the confidence to take on more complex work
or deploy novel materials and designs. An effective and structured weldability
study offers;
 right first time solutions
 impartial selection of technologies
 advice on recent developments of conventional technologies
 innovative joining capabilities
 improved differentiation and competitiveness

See also: 6b.4
Prediction of weld quality

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6d. Manufacturing problems and opportunities

6d.3 Options for joining complex geometrical features
Components with complex geometries are widely used throughout many industry
sectors. However conventional joining technologies are often not robust enough
for complex geometries. This can cause issues which risk severely deteriorating
the integrity of welded components. If unaddressed, these issues create additional
rework or scrap, or can impact on the reputation of the business.

Drivers

Distortion and residual stress caused by the heat input during welding can severely
damage heat sensitive materials. Conventional joining methods are not always
capable of handling complex geometries. High accuracy control systems to handle
these are an integral part of advanced joining processes. Independent expert advice
and support can;
 provide an overview of joining methods
 identify optimum joining methods for the particular geometry
 identify potential for productivity and efficiency improvements
 recommend optimum parameter ranges to manage heat input

Summary approach

Robust and complete capture of all component requirements and all business needs
is the first step in resolving any technological issue. Joining processes suitable for the
specific weld geometry are identified. Expert consultations to explore parameters and
to optimise the joining process should then take place. This will allow an appropriate
experiment to be designed.

Identify Consult Conduct Evaluate Recommend
experiment

Running a structured experiment allows the business to test potential solutions.
These may include thermal management and the use of high accuracy control
systems. Post processing options also need to be evaluated. From the structured
experiments, a range of solutions based on customer requirements can be identified.

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Benefits

The capability to join complex geometric features allows a business to take on more
intricate and complex work cost effectively. Identifying and embedding the best
joining solution ensures productivity by maintaining thorough control of the process.
It will result in;
  a higher quality product with increased accuracy and integrity
  higher productivity
  lower scrap – right first time
  improved thermal management
  improved customer satisfaction

See also: 6b.4
Prediction of weld quality

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6d. Manufacturing problems and opportunities

6d.4 Options for machining with high temperature alloys
New heat resistant alloys are difficult to machine and conventional machining
strategies are often not suitable for production requirements. Poor tool
performance and reduced life span can cause delivery delays and increased costs.
This can present a challenge to a business wanting to meet customer requirements
and protect margins.

Drivers

To accommodate customer and market demands for the machining of exotic
materials, a business needs to consider alternative techniques and methods. Using
a systematic process to identify the best machining options can improve resource
efficiency and deliver a higher quality product in a more cost effective way. With
expert support a business can;
  explore novel methods for machining exotic materials
  identify potential for productivity and efficiency improvements
  understand the benefits of modern tooling technology
  evaluate potential for new complete manufacturing solutions

Summary approach

The first step is to evaluate the current processes being used to machine high
temperature alloys. What are the current capabilities and constraints? What are
the performance requirements of the components and the business needs?
Then investigate and review what alternative technology, tools and techniques
are available.

Evaluate Investigate Trial Analyse Implement

After downselection, suitable methods and technology are trialled. It is an advantage
if these trials are run in an impartial environment.

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Fig 6d.4.1: Machining of HT alloy at Arrowsmith Engineering

The results of the trials are analysed and recommendations made for improvements
to technology, techniques, or both. Improvements selected then need to be
implemented and embedded throughout the business.

Benefits

A key benefit is increased product confidence through the development of standard
processes for machining exotic materials. Additionally, the development of new
techniques can improve tool life and efficiency, which increase both productivity and
the financial viability of the process. Other benefits include;
  improved finish quality
  improved accuracy
  reduced energy consumption
  increased capacity

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Case study:
Arrowsmith Engineering needed to develop new thread-rolling processes. Thread-
rolling is a difficult cold forming process which can be performed on any ductile metal
to produce smooth and precise threads.
MTC engineers worked closely alongside Arrowsmith’s own team, reviewing the whole
process from start to finish, developing precision-controlled production techniques.
These techniques were tested in small batch trials before being successfully carried over
to volume manufacture.
The innovative technologies employed have allowed Arrowsmith to produce
components that could previously not be made to the standard of accuracy and
quality achieved.
“We’ve all been impressed by their modest attitudes and exceptional knowledge of
the MTC engineers. As a result, we’ll be manufacturing components that couldn’t
previously be made.”
Jason Aldridge, managing director, Arrowsmith Engineering
Arrowsmith Engineering, based in Coventry, manufactures bespoke components
for aerospace clients, handling metals including titanium and magnesium

See also: 5c.4
Discovering value from simulation tools 8.3
Embedding effective use of standard work

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6d.5 Options for post processing additive layer parts
The complexity of a part may make it difficult for a business to automate the
finishing process easily. This can be a particular challenge to businesses using, or
wishing to use, additive manufacturing processes. Such processes can present a
business with parts which have a very rough surface and complex geometry.

Drivers

Hand finishing of parts can be a slow and costly process. The difficulty of consistently
controlling finished and post-processed parts can also lead to reduced quality. Health
and safety issues associated with using polishing and grinding processes may also
require additional capital expenditure on safety equipment. Using expert support to
identify the best machining options can;
  provide an overview of finishing process capability
  identify the right solution for the specified problem
  identify potential for deploying a robotic flexi-finish cell
  provide an overview of potential benefits
  provide case studies

Summary approach

The first step is to evaluate current finishing processes. What are the current
capabilities and constraints? What are the performance requirements of the
components and the business needs? Expert use of optical geometry scans will
provide dimensional and surface texture data. This enables downselection of the best
finishing process, or combination of processes, based on the agreed requirements.

Identify Determine Define Evaluate Recommend
requirements finishing measurement results strategy
strategy
strategy

The objective is, firstly, to determine and recommend a combination of post-
processes to create an efficient and flexible process that can be used on the
majority of parts. If feasible, these processes will be automated to reduce time,
cost and variation.

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Fig 6d.5.1: Additive layer post production part

Benefits

A key benefit of optimising, and if feasible automating, finishing processes is the
ability to handle more complex parts. This increases the diversity of industry sectors
that can be catered for. Other benefits include;

  increased control of the process
  improved quality
  a reduction in finishing time
  improved productivity
  significant savings from choosing the right solution first time
  market diversification is enabled

See also: 5e.2
Minimise risk of inserting additive technology

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Chapter 6e

Material analysis

Introduction
 6e.1 Powder characterisation analysis
 6e.2 Assessment of powder supply
chain options
 6e.3 Rapid metal deposition –
capability demonstration

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6e. Material analysis

Introduction
Many new manufacturing technologies require a supply of powder materials. These
need to be appropriate for the specific technology, available in the right quantity and
of a consistent quality to enable robust manufacturing processes.
The value accelerators in this chapter address the need for an understanding of
powder materials and the means of sourcing them in sufficient quantity and at the
right time. A simulation tool to model rapid metal powder deposition is also included.
A business may also need expert material analysis advice on microstructure
characterisation and optimisation. Such analysis is important to ensuring that the
material input to powder based technologies is understood and controlled, in order
to give consistent product quality.
Expert support on metallurgical failure analysis will enable a business to carry out
detailed root cause analysis of specific failures and to determine the best corrective
actions to ensure they are not repeated.

Fig 6e.1: Analysing metal powder in the MTC powder analysis laboratory Page 191
6. How can technology help?

6. How can technology help?

6e. Material analysis

6e.1 Powder characterisation analysis
Powder metallurgy technologies use metal powder as raw material.
Characterisation of its quality and consistency is critical to the process.
Having the right powder specifications is key to achieving a consistent
performance from the final component.

Drivers

Using powders with unknown properties can risk compromising the integrity of the
manufacturing process and final component. Testing for alloy composition alone is
not enough to guarantee process performance. A business will require full powder
characteristic analysis where;
  chemical consistency does not ensure physical consistency
  physical differences in powder may lead to process behaviour differences

Or where there is a need to;
  identify variations between batches that process differently
  reduce component performance variability
  ensure batch quality specifications are met consistently

Summary approach

The first step is to understand and fully capture all requirements of the specific
manufacturing process or component. What does the business need? What are the
key process variables? This identifies and clarifies potential powder processing issues.
The most appropriate testing methods will depend upon the specific powder key
process variables.

Identify Propose Sample Analyse Report
requirements testing and test results powder
regime properties

Samples of the powder are tested and analysed. Any gaps between required and
actual performance is highlighted. Results are then reported, with recommendations
on how specific performance gaps can be closed.

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6e. Material analysis

Fig 6e.1.1: Metal powder details

Benefits
By applying state of the art characterisation techniques it is possible to understand
better the behaviour of a powder. Material and process specifications can be
improved by identifying the key process variables that control performance.
The main benefits of powder characterisation are;
  identification and control of key process variables
  ensuring batch to batch consistency
  assessing the feasibility of alternative materials
  improving manufacturing process capability
  improving component quality and consistency

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6e. Material analysis

6e.2 Assessment of powder supply chain options
Any manufacturing business using, or planning to use, powder metallurgy
technologies requires a robust powder supply chain. Only with this in place can it
ensure consistent quality and delivery to its own customers. The best supply chain
option can be selected by assessing available materials, market trends for metal
powders and potential suppliers.

Drivers

Having the right supply chain in place up front de-risks the decision to invest in
powder metallurgy technologies such as net shape or additive layer manufacturing.
A poor choice of supplier or inappropriate feedstock material is a missed opportunity
for the business. Taking independent, expert advice will make the supply chain
assessment process more robust. It can help;

  identify the best powder supply chain route
  identify the costs and benefits of powder types on the market
  clarify the advantages and costs of diverse supply routes
  obtain up to date information on market trends
  offer an update on new materials on the market
  support the development of new manufacturing processes

Summary approach

The first step is to capture all the business requirements and identify the capabilities
and constraints of any current powder supply chain. Information on supply chain
options needs to be gathered from both suppliers and available academic literature.

Understand Gather Analyse Select Provide
customer information various optimum recommend-
requirements from suppliers options supply chain
available ation

The suitable supply chain solutions are highlighted and analysed. What are
the pros and cons for each option? Which option provides the closest fit with the
defined requirements of the business?

The optimum supplier is identified and a powder supply chain
recommendation made.

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6e. Material analysis

Benefits

Any current powder based manufacturing process can be improved by ensuring the
powder supply chain choice is appropriate for the business. Investment decisions for
planned future processes can be de-risked by the identification of the ideal supply
chains. Benefits of robust powder supply chain analysis include;

  clarifying all the options available
  awareness of latest market trends and materials
  securing customised and up to date powder supply chains
  identifying the supply chain route best suited to the business
  improving the current manufacturing process
  supporting and de-risking development of new processes

See also: 5a.2
Key questions for your technology vendor 5a.1
Validating the market case

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6e. Material analysis

6e.3 Rapid metal deposition–capability demonstration
Using software to model shaped metal deposition (SMD) and additive layer
manufacturing (ALM) processes de-risks the use of these technologies. It allows a
business to manipulate geometry, tool path, heat source and material properties to
achieve the best result.

Drivers
Modelling and visualisation of rapid metal deposition through simulation software
allows quicker, more robust decisions.
It identifies potential problems – for instance issues with thermal expansion of molten
metal – in a low cost, risk-free way. It also;
  reduces number of trials needed before manufacture
  provides a method to measure the accuracy of the process
  allows identification of faults before manufacture
  assesses performance and safety before manufacture

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6e. Material analysis

Summary approach

First, define the part and properties to be modelled. Model the representative 3D
finite element model for the simulation.

Define Model Analyse Identity Recommend

Analyse, the model process and parameters and identify the discrepancies between
the original design and the achievable end result.

Finally, recommend changes to the design to minimise any deformations found.
Repeat the simulation until an optimum result is achieved.

Thermo-Mechanical FEA of Specimen Calibrate Analytical Thermal Model
Analytical Thermal Model
Analytical Thermal Model NO
Analytical Thermal Model FEA Validation of 3D Components

Experimental and Predicted
Distortion Satis es the
Scaling Criterion?
YES

Thermo-Mechanical FEA of Components
Analytical Thermal Model
Analytical Thermal Model
Analytical Thermal Model

Fig 6e.3.1: ALM predictive methodology

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6e. Material analysis

Benefits

Use of software to model shaped metal deposition (SMD) and additive layer
manufacturing (ALM) reduces costs by enabling a business to achieve right first time.

Working with an expert partner already in possession of the software allows a
business’s engineers to focus on the design outcome rather than the physics behind
the model. Other benefits include;
  feasibility testing without capital investment
  reduced development costs
  more rapid development of innovative new products
  de-risking engagement with a complex new technology

Investment in a licence for rapid metal deposition modelling software and
embedding the necessary knowhow for future applications gives additional benefits.

A single application allows rapid what if analysis on the effect of changing geometry,
tool path, heat source and material properties parameters. It;
  allows non-experts to carry out multi-physics analysis
  allows quick multiple remodelling

See also: 6c.2
Demonstrate net shape equipment and process 6c.3
Design for net shape – capability demonstration 6c.4
Design for additive manufacturing – capability demonstration

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7. Levering benefit from technology

Introduction
The value accelerators in previous chapters addressed tools and techniques to de-risk
the planning and implementation phases of new technology adoption.
The value accelerators in this chapter offer advice on how to ensure that investment in
innovation and technology delivers the expected benefits.

Fig 7.1: Demonstrator - embedded sensors. Embedded sensors offer a manufacturing business the
ability to control a process actively, reduce down time and prevent potential processing errors. This is
achieved by developing a smart fixture which includes feedback, control and automatic responses
dependent on what is happening to a part in real time.

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