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Qualification process development for metal additive manufacturing - A study for the establishment of additive manufacturing at Alfa Laval

Svensson, Klara LU and Laurén, Josefine (2020) MMKM05 20201
Product Development
Abstract (Swedish)
Den additiva tillverkningsprocessen och kvalificeringen av komponenter i metall är komplex och tillverkningsmetoden är inte ännu fullständigt förstådd. Syftet med detta examensarbete är därför att förvärva kunskap om kvalificeringsprocesser kopplade till additiv tillverkning i metall och att utveckla en hållbar kvalificering för additivt tillverkade komponenter hos Alfa Laval. Kvalificeringsprocedurerna avser att försäkra att de additiva tillverkningsprocesserna fungerar och utförs som förväntat. Forskningen bestod av en litteraturstudie och en fallstudie uppdelad i intervjuer inom industrin och datainsamling hos Alfa Laval.

Inga generella kvalificeringsprocesser för additiv tillverkning upptäcktes i litteraturstudien. Istället visade... (More)
Den additiva tillverkningsprocessen och kvalificeringen av komponenter i metall är komplex och tillverkningsmetoden är inte ännu fullständigt förstådd. Syftet med detta examensarbete är därför att förvärva kunskap om kvalificeringsprocesser kopplade till additiv tillverkning i metall och att utveckla en hållbar kvalificering för additivt tillverkade komponenter hos Alfa Laval. Kvalificeringsprocedurerna avser att försäkra att de additiva tillverkningsprocesserna fungerar och utförs som förväntat. Forskningen bestod av en litteraturstudie och en fallstudie uppdelad i intervjuer inom industrin och datainsamling hos Alfa Laval.

Inga generella kvalificeringsprocesser för additiv tillverkning upptäcktes i litteraturstudien. Istället visade det sig finnas komplexa kvalificeringskrav på både komponent och process. Från intervjuerna uppdagades det att kvalificeringsprocesser för additiv tillverkning inom industrin skiljer sig åt mellan företag. Dessutom underströks vikten av att behandla additiv tillverkning likt andra tillverkningsmetoder.

Baserat på forskningen utvecklades och presenterades ett kvalificerings- ramverk i detta examensarbete. I konceptet ställs krav på fyra kvalificeringssteg: råmaterial, utrustning, komponent och process samt prestanda. Det generella konceptet utvecklades till en strategi baserad på Alfa Lavals intressen, avseende kvalificering baserat på komponenters kriticitet. En andra strategi angående produktfamiljer presenterades också. Arbetet som presenterades validerades genom återkoppling från experter inom additiv tillverkning.

Sammanfattningsvis så hade ett mer standardiserat förhållningssätt till kvalificering och arbetssätt inom additiv tillverkning varit till nytta för industrin. Kvalificeringsprocesser är involverade i produktutveckling vilket kräver tidig inblandning av olika funktioner inom en organisation. (Less)
Abstract
The process of additive manufacturing and qualification of components in metal is complex, and the manufacturing method is still not fully understood. Therefore, the purpose of this thesis is to gather knowledge of the qualification procedures connected to additive manufacturing in metal and to develop sustainable qualification for additively manufactured parts at Alfa Laval. The qualification procedures aim to ensure that the additive manufacturing procedures operates and performs as expected. The research was conducted through a literature study and a case study consisting of interviews within the industry and data collection at Alfa Laval.

No general qualification process for additive manufacturing was found in the literature study.... (More)
The process of additive manufacturing and qualification of components in metal is complex, and the manufacturing method is still not fully understood. Therefore, the purpose of this thesis is to gather knowledge of the qualification procedures connected to additive manufacturing in metal and to develop sustainable qualification for additively manufactured parts at Alfa Laval. The qualification procedures aim to ensure that the additive manufacturing procedures operates and performs as expected. The research was conducted through a literature study and a case study consisting of interviews within the industry and data collection at Alfa Laval.

No general qualification process for additive manufacturing was found in the literature study. Instead, the result showed complex qualification needs for both part and process. The conducted interviews showed that the qualification processes for additive manufacturing within the industry differs between companies. It was also highlighted that additive manufacturing should be considered as any other manufacturing method.

Based on the research, a qualification framework was developed and presented in this thesis. In the concept, there are four steps of qualification required: raw material, equipment, part and process and performance. This general concept was developed into a strategy based on Alfa Laval’s interests, concerning qualification based on part criticality. Another strategy regarding product families is also presented. The presented work was validated by feedback from experts within additive manufacturing.

In conclusion, a more standardised approach of qualification and way of working with additive manufacturing would be in order across the industry. Qualification procedures are also involved in product development which demands early involvement of different functions within an organisation. (Less)
Please use this url to cite or link to this publication:
author
Svensson, Klara LU and Laurén, Josefine
supervisor
organization
course
MMKM05 20201
year
type
H2 - Master's Degree (Two Years)
subject
keywords
additive manufacturing, qualification process, laser powder bed fusion, metal AM, 3D-printing, qualification of AM, additiv tillverkning, kvalificeringsprocess, laser-pulverbäddsfusion, metall-AM, 3D-printning, kvalificering av AM
language
English
id
9017977
date added to LUP
2020-06-15 10:01:16
date last changed
2020-06-16 03:39:44
@misc{9017977,
  abstract     = {The process of additive manufacturing and qualification of components in metal is complex, and the manufacturing method is still not fully understood. Therefore, the purpose of this thesis is to gather knowledge of the qualification procedures connected to additive manufacturing in metal and to develop sustainable qualification for additively manufactured parts at Alfa Laval. The qualification procedures aim to ensure that the additive manufacturing procedures operates and performs as expected. The research was conducted through a literature study and a case study consisting of interviews within the industry and data collection at Alfa Laval.

No general qualification process for additive manufacturing was found in the literature study. Instead, the result showed complex qualification needs for both part and process. The conducted interviews showed that the qualification processes for additive manufacturing within the industry differs between companies. It was also highlighted that additive manufacturing should be considered as any other manufacturing method.

Based on the research, a qualification framework was developed and presented in this thesis. In the concept, there are four steps of qualification required: raw material, equipment, part and process and performance. This general concept was developed into a strategy based on Alfa Laval’s interests, concerning qualification based on part criticality. Another strategy regarding product families is also presented. The presented work was validated by feedback from experts within additive manufacturing.

In conclusion, a more standardised approach of qualification and way of working with additive manufacturing would be in order across the industry. Qualification procedures are also involved in product development which demands early involvement of different functions within an organisation.},
  author       = {Svensson, Klara and Laurén, Josefine},
  keyword      = {additive manufacturing,qualification process,laser powder bed fusion,metal AM,3D-printing,qualification of AM,additiv tillverkning,kvalificeringsprocess,laser-pulverbäddsfusion,metall-AM,3D-printning,kvalificering av AM},
  language     = {eng},
  note         = {Student Paper},
  title        = {Qualification process development for metal additive manufacturing - A study for the establishment of additive manufacturing at Alfa Laval},
  year         = {2020},
}