ADDITIVE MANUFACTURING PROJECT CLUSTER MEETING Fundació CIM C/Llorens i Artigas, 12 Parc Tecnològic de Barcelona Barcelona, Spain ADDITIVE MANUFACTURING PROJECT CLUSTER MEETING AM for Metal Parts AATiD– The Israeli National Consortium for Additive Manufacturing 2 May 2016

Introduction Technion – Israel Institute of Technology The largest Israeli comprehensive academic center for advanced science and technology education, as well as applied research Technion R&D Foundation - a bridge to the industry Israel Institute of Metals (IIM) Additive Manufacturing Lab. Leading academic partner in AATiD consortium

AATiD - Advanced Additive Titanium Development Consortium PROJECT DESCRIPTION AATiD - Advanced Additive Titanium Development Consortium Established within the support of the Israeli Office of the Chief Scientist (OCS), Magnet Committee. Develop Advanced Technologies for Design and Three-Dimensional Printing of Optimized Complex Aero-structures made of Titanium alloys.

PROJECT DESCRIPTION AATiD’s Main Focus: The Need The aviation market is pursuing for high-performance aero-structures at a competitive price. This becomes ​​possible with complex geometries that could be manufactured only by Titanium printing. The Vision Upgrade the Israeli aero-structures industry by exploiting existing technologies that could design and print these optimal aero-structures. The Target Develop the ability to design and manufacture geometrically complex aero-structures which can be manufactured only additively. The Technology Powder bed, moderate size using ARCAM A2X, EOS M290 (both are located in IIM). The Material Ti-6Al-4v grade 5 - superior characteristics in competitive cost, easily welded compared to Aluminum, could be tested according to ASTM F2924 − 14: Standard Specification for Additive Manufacturing Titanium-6 Aluminum-4 Vanadium with Powder Bed Fusion.

Printing & Joining Group Materials & Post -Processing Group PROJECT DESCRIPTION AATiD’s Organization Chart: Chairman Mr. Lior Zilberman Ministry of economy- Israeli Chief Scientist Magnet Committee * Technology Manager Board CFO: CPA Legal Advisor Scientific Technology committee Design Group Printing & Joining Group Materials & Post -Processing Group The Civil Aviation Authority of Israel, CAAI * Magnet Committee: Development of  generic innovative  technologies, involving collaboration and synergy between Israeli industry and Academia, in order to  create a competitive advantage to Israeli industry in high growth rate and significant global marketplaces The Israeli Air Force

Exploitable results (ERs) Point ER1 ER2 ER3 Description Optimal processes for printing, welding and post-processing of Ti printed parts Selection of the most appropriate powder bed printer and most worthwhile parts to be printed @ specific technology Design rules of bionic parts based on topology optimization combined with printing technologies limitations Type Process Innovation Performance, repeatability, affordability Performance, affordability Benefits (customers, partners, public, etc.) Optimal fully production cycle Optimal printer Worthwhile parts to be printed @ specific technology Optimal parts with minimum technological supports TRL 6 7 Technical barriers Many variables Change of mind-set Time to market (year) 1 Investment cost (K$) 1000 700 Protection (how, when) Internal IP

Statement of WORK (SOW) vs. TRL # Description TRL 1 Methodology for the establishment and operation of an aero-structures production line based on powder bed printers 4 2 Methodology for using alternative and recycled powders 3 Prediction of EB printed Titanium properties using process simulation software Methodology for the development of a design allowables matrix 5 Methodology for choosing the most effective NDT per geometry and defects 6 Methodology for the development and justification of lattice structures 7 Embodiment of Civil Aviation Authority regulations in printed aero-structures 8 Methodology for scanning damaged part and fast recovery by printing a complete replacement 9 Methodology for selection of the appropriate optimization software and the appropriate simulation software 10 An atlas of fractographic images of printed Ti-6Al-4V 11 A novel electro-polishing process for printed Ti-6Al-4V parts

AATiD members: Existing experience & Other AM projects experience - Products Hinge, PH15-5, by EOS Elbit Cyclone Prototype of fuel tank for nanosatellite (Ti-6Al-4V) IIM HINGE Main Entrance Door “GOOSENECK” Original Material: 15-5PH Steel Alternative Material : Titanium alloy 52% Weight Reduction Emergency Door Lock Cover “SPIDER” Original Material: Al 7050 T7451 Alternative Material: Al-Mg-Sc alloy Multidisciplinary optimization including material change from Steel to Titanium alloy with no deterioration in strength and fatigue allows 52% Weight Reduction. welding and machining elimination . Electron Beam Melting + HIP was applied . IAI in cooperation with EADS IW, UK Hinge, AlSi10Mg, by EOS Elbit Cyclone Novel High strength Al alloy Scalmalloy™ and Selective Laser Melting were applied to reach 15:1 Buy-to-Fly ratio . IAI in cooperation with TWI, UK and EADS APWORKS , Germany

AATiD members: Existing experience & Other AM projects experience - Process 2kW diode laser welding of additive manufactured pipes (Ti-6Al-4V) IIM Investigation and modelling of thermal behavior during EBM-AM Technion Electro-polishing process for AM Development of EP process for Ti-6Al-4V ELI parts made by EBM-AM technology using environmental friendly electrolyte (IIM) Corrosion Investigation BGU Fractography Technion

Expressions of Interest Mapping of most relevant partners for clustering: M1-US-QUESTEK, M2-US-EXOVA, M6-SA-MEDAERO, M9-EU-AMAZE, M11-EU-RepAIR, M14-EU-NANOTUN3D, GT11-EU-FOFAM. New magnets (H2020 “NOVAMAG”) / production of ferrite powders for AM: M10-EU-REProMag. General missing knowledge: Effective process control systems, characterization of the creep properties of titanium, GR & R of equal Ti-6Al-4V printing and characterization, prediction of laser printed Titanium properties using process simulation software, development and perform a design allowables matrix of lattice structures, fatigue properties of lattice structure, joining of lattice structures, develop procedures for health monitoring of printed items. Production and characterization of new alloys for AM powder. Seeking for collaboration as AATiD consortium or as individual partners (Technion IIM, IAI, Elbit Cyclone, etc.). Besides the AM clustering, interested in joining H2020 projects, as well as the clean sky program, bird foundation and other bi/multi-lateral activities. For more information please contact: Daniel Safranchik, DaniS@trdf.technion.ac.il (Web: IIM.Technion.ac.il) AATiD Chairman: Mr. Zilberman Lior,  Lior.zilberman@elbitsystems.com AATiD Technical Management: Dr. Lucy Edery-Azulay, Lucy.AATiD@gmail.com (Web: AATiD.co.il)