Dr. Thomas Haubold
Rolls-Royce Deutschland Ltd & Co KG
Thomas studied Material Science at the Universität des Saarlandes in Saarbrücken in the 80s followed by a PhD - Thesis on the atomic grain boundary structure of nanocrystalline materials.
After a 3 years Post Doc position at the Institute for New Materials working on nanostructures intermetallic phases, he joined Rolls-Royce Deutschland in 1992. The career started at the Materials Laboratory with materials and manufacturing technology R&T as well as process control for special processes. This was followed by some years in operation as production lead and manufacturing engineering manager in the special process plant. Today Thomas holds a specialist function in the Manufacturing Engineering team as Engineering Associate Fellow for Special Process, certified Black Belt and Global Process Owner for Surface Conditioning processes.
Abstract: Surface Enhancement Processes in Aeroengine Component Manufacturing
Special processes play a crucial role in the engineering and manufacturing of aeroengine components. Process characteristics are explained and examples of surface enhancement processes used in the manufacturing of critical aeroengine components such as compressor blisks and turbine discs will be given describing requirements as well as effects on engine performance and life. Trends, challenges and development needs will be discussed to ensure cost effective application of surface enhancement in the future.
Professor Hong Minghui
National University Singapore
Prof. Hong Minghui specializes in laser microprocessing & nanofabrication, optical engineering and laser applications. He has co-authored 12 book chapters, 40+ patents granted, and 400+ scientific papers in Nature, Chemical Reviews, Nature Nanotechnology, Advanced Materials, Advances in Optics and Photonics, Nano Letters, Light: Science and Applications, ACS Nano, Science Advances, Nature Communications, and Laser & Photonics Reviews etc. and 70+ plenary/keynote/invited talks in international conferences. He is a member of organizing committees for Laser Precision Micromachining International Conference (2001~2019), International Symposium of Functional Materials (2005, 2007 and 2014), Chair of International Workshop of Plasmonics and Applications in Nanotechnologies (2006), Chair of Conference on Laser Ablation (2009) and Chair of Asia-Pacific Near-field Optics Conference (2013 and 2019).
Prof. Hong is invited to serve as an Editor of Light: Science and Applications, Associate Editor of Science China G, Editor of Laser Micro/nanoengineering, and Executive Editor-in-chief of Opto-Electronic Advances. Prof. Hong is Fellow of Academy of Engineering, Singapore (FSEng), Fellow of Optical Society of America (OSA), Fellow of International Society for Optics and Photonics (SPIE), and Founding Fellow and Vice President of International Academy of Photonics and Laser Engineering (IAPLE) and Fellow and Council Member of Institute of Engineers, Singapore (IES). Prof. Hong is currently a Full Professor and the Director of Optical Science and Engineering Centre (OSEC), Department of Electrical and Computer Engineering, National University of Singapore. He is also the Chairman of an NUS spin-off company Phaos Technology Pte. Ltd.
Abstract: Laser Processing and Signal Diagnostics for In-situ Process Monitoring
Laser processing has unique advantages as a non-contact means with flexible setup and high speed processing in advanced manufacturing. In the past decades, we have witnessed its extensive applications from academic researches to production lines. Combined with other advanced processing tools, laser processing’s resolution can even be pushed down to <50 nm, which will play a much more important role in next-generation nano-manufacturing. In this talk, our research progress on dynamic laser-materials interactions and signal diagnostics for in-situ process monitoring will be reviewed. How to achieve small heat affected zone (HAZ) is a key issue in high quality laser precision engineering in micro/nano-scales. Hybrid laser processing can lead to laser manufacturing of difficultly processed samples, such as heat sensitive and ultra-thin substrate devices. Optimization of laser-materials interactions can provide us novel approaches to overcome processing challenges. To increase laser processing speed, a few parallel (multi-beam) direct-write laser processing techniques are successfully developed. Meanwhile, our researches show that there are rich acoustic wave, electric, magnetic and optical signals being generated during laser processing. Fast signals’ acquisition and study of the physics behind the signals’ generation provide us excellent opportunities to build various processing parameters’ databases and achieve process real-time monitoring, which optimizes laser advanced manufacturing efficiency and throughput.
Dr. Takashi Sato
Dr Takashi Sato studied the precision engineering at Utsunomiya University in Japan and obtained a PhD degree from the same University. The career started at Akita Prefectural University in Japan as an assistant professor with the development of a special surface finishing process called magneto-rheological finishing (MRF) for difficult-to-finish areas and materials. After 2 years, he joined Singapore Institute of Manufacturing Technology (SIMTech) in 2010 and led abrasive process team and worked on several industrial projects using the MRF, Abrasive Flow Machining (AFM) and Vibratory Finishing, etc. He transferred to Advanced Remanufacturing and Technology Centre (ARTC), Singapore in 2014, and worked on the research of surface finishing of additively manufactured (AM) parts using the AFM for aerospace application as a technical lead of surface enhancement group. In 2017, he joined to corporate R&D division in IHI Corporation, Japan. Today he holds a role as a senior researcher in application research on the post-process of the AM parts for aero-engine application. He has co-authored 2 book chapters, published 25+ papers through his career and holds several patents.
Abstract: Surface Finishing Techniques for EBM-Manufactured Ti-6Al-4V Components
Surface finishing of additively manufactured components is a challenge due to inherent rough surface and complex geometries. This paper studies the comprehensive strategy to efficiently obtain the required surface quality using various surface finishing techniques for Ti-6Al-4V components made by powder-bed fusion electron beam melting (EBM). The fundamental performances of conventional and non-conventional surface finishing techniques for both external and internal surfaces are evaluated. In addition, techniques for support structure and powder cake removal are discussed, as they have an impact on productivity.
Professor Hitoshi Soyama
Prof. Hitoshi Soyama is known for his work in the fields of cavitation damage and practical applications of cavitation impact, i.e., cavitation peening. As is well known that cavitation impacts causes severe damage in hydraulic machineries, his research utilized cavitation impacts for enhancement of fatigue properties of metallic materials. He was awarded as a Fellow of American Society of Mechanical Engineers ASME with a recognized achievement of cavitation peening, a Fellow of Japanese Society of Mechanical Engineers JSME, a Fellow of Society of Automotive Engineers of Japan SAEJ and a honorary member of Water Jet Technology Society of Japan.
He has been working at Tohoku University since 1991 after he got his PhD from Tohoku University, Japan, in hydrodynamic research on scale effects of severe cavitation erosion. He is Director of Center for Surface Modification
Engineering, Division of Mechanical Engineering, Tohoku University since 2001. He was promoted to a professor at 2003. He has co-authored 10 book chapters, 240+ scientific papers and 15 plenary/keynote/invited talks in international conference such as 1st NASA Cross Industry Innovation Summit, Space Center Houston, 2016, and he presented about “Using in Situ Resources for 3D manufacturing on Mars” at the summit.
Abstract: Fundamentals and Applications of Cavitation Peening Comparing with Shot Peening and Laser Peening
In the key plenary talk, fundamental and application of cavitation peening will be presented comparing with shot peening and laser peening in the view point of improvement of fatigue strength of metallic materials. Normally, cavitation is harmful phenomenon for hydraulic machineries such as pumps and valves, as cavitation causes severe impact at cavitation bubble collapse. However, the impact can be utilized for the mechanical surface treatment of metallic materials as same way as shot peening. The peening using cavitation impact is named as “cavitation peening” or “cavitation shotless peening”, as shots are not required. At the presentation, the concepts and key factors on cavitation peening using a submerged water jet was revealed experimentally. The difference on improvement of fatigue strength of stainless steel treated by was demonstrated by using a plane bending fatigue test. The distribution of compressive residuals stress introduced by cavitation peening, shot peening and laser peening at constant arc height of Almen strip was measured by an X-ray diffraction method. The individual plastic deformation introduced by cavitation peening, shot peening and laser peening also investigated using Fry etching method.
A/Professor Hu Yongxiang
Shanghai Jiao Tong University (CN)
Dr. Yongxiang Hu specializes in laser peening. He received his B.S. degree in Mechanical Engineering from Nanjing University of Science & Technology in 2003 and Ph.D. degree in Mechanical Engineering from Shanghai Jiao Tong University (SJTU) in 2008. Then he joined as an assistant professor in SJTU. He has served as an associate professor in the School of Mechanical Engineering, Shanghai Jiao Tong University since 2013. And his research has published more than 20 journal papers and holds several patents. He will Chair of 8th International Conference of Laser Peening & Related Phenomena in 2020.
Abstract: Efficient Modeling of Laser Peening for Residual Stress and Shape Control
Laser peening is proposed as an effective mechanical process to improve fatigue resistance for components and shape panels with complex geometry in the aerospace industry. Modeling of laser peening process for process design is of great desire to reduce development time and cost for applications in high-value components. Modeling of laser peening process spot-by-spot is computationally expensive due to the long duration to capture the transient response of the material for each shock. To overcome high computation cost, eigenstrain has been developed to predict the effect of large-scale laser peening more efficiently compared with previous methods. In the developed eigenstrain-based method, residual stress and deformation fields are analyzed elastically using the eigenstrain as initial strain in the model. And the eigenstrain varied by process conditions is inversely determined by combining experiments and simulation. Residual stresses on the surface with complex geometry is predicted with the eigenstrain-based modeling method. Furthermore, eigenmoment, derived from eigenstrain, is proposed to describe the bending behavior of metal plates in laser peen forming. To achieve process planning of laser peen forming, the distributed eigenmoment on two surfaces of the plates is prescribed, and a PDE-constrained optimization is utilized to describe the process planning problem for complex shaping. This optimization method is characterized by high-efficiency and wide-ranging versatility, which is demonstrated by saddle shaping.
Dr. Domenico Furfari
Airbus Operations GmbH
Dr. Domenico Furfari is Technical Advisor for Structural Analysis at the Airbus Airframe Competence Centre. His professional background is structural analysis in the field of fatigue and damage tolerance of metallic airframes. He obtained his Engineering degree from the University of Pisa, Italy, awarded with 110/110 from the Aerospace department in the field of Aeronautic Structures. After a short stay at the University of Pisa as a research assistant, he moved to Cranfield University, UK, where he obtained his PhD from the School of Industrial and Manufacturing Science with a thesis on "Fatigue Short Crack Behaviour of Ti-10-2-3 Alloy for Helicopter Structural Applications".
He joined Airbus Operations GmbH in Hamburg, Germany, in 2004 and worked in the repair department for fatigue and damage tolerance as Airbus Germany site coordinator for the EU Project (FP6). Since 2006, he has coordinated and led various research and technology projects at Airbus. Most projects are carried out in cooperation with
Abstract: An Overview of the Requirements for Implementing Laser Shock Peening into Aerospace Industry
The development of Laser Shock Peening (LSP) needs multidisciplinary skills, from optical to automation engineering. From the Aerospace Industry prospective the development of a laser system is just the first step. The capability to extend the fatigue live of an aircraft component and/or to slow down the crack growth should be demonstrated. This paper provides the minimum requirements to demonstrate acceptable mechanical performance after LSP, in terms of compressive residual stress profile and fatigue responses. Possible coupons geometries, taking into account the possibility to be tested in standard mechanical test laboratories are described. These tests alone are not sufficient for the qualification and certification to enter in service, but they represent a possible preliminary test campaign to prove minimum requirement in terms of mechanical performance.
Robustness, repeatability and stability of the LSP process are key features to ensure the process effects to be predictable and repeatable, taking into account statistical quantification. Integration of In Process Assurance Quality indicators may be a solution to limit Destructive and Non Destructive serial testing during operations. Continuous operational peening up to 3 shifts work should be ensured without disruption in production. In service, the system will operate all around the world in various environments showing the need for supply chain reactivity. The system should be “easy to handle”, providing appropriate training to Third Parties to operate and maintain it. Finally, as part of Towards Industry 4.0, the requirements of an advanced fully automatized forming processes, including an embedded online metrology system will be presented. This includes reshaping straightening as necessary due to the imparted distortions resulting from partial release of residual stresses introduced by previous manufacturing steps of direct machining of aluminum integral parts from very thick plate at final temper.
Dr. Yuji Kobayashi
Dr. Yuji Kobayashi is Group Manager of Development Group, SURFACETEC COMPANY in SINTOKOGIO, LTD., Japan. After graduation of master course, he was employed in SINTOKOGIO. Then he has been working over 20 years. During this period, he is organised in development team. On the way, he was worked in TOYOTA as a guest engineer for 3 years. At that time, he learned carburizing process, material and specification of gear at TOYOTA.
In 2013, he was received a Doctor of Engineering degree. He applied for 38 domestic applications in 22 years of experience and 24 patents were established.
He is a member of SAE Surface Enhancement Committee, the SAE Aerospace Surface Enhancement Committee and the International Scientific Committee on Shot Peening and also, Shot Peening Societies in Japan. These activities were evaluated and he was awarded a shot peening of the year in 2018 from Shot Peener magazine.
Abstract: Transition of Shot Peening Technology in Japanese Automobile Industry
In Japan, shot peening technology has been studied and investigated around 1950. At that time, it seems that they learned shot peening technology by maintaining the equipment of the US military. Since then, shot peening has been considered mainly to use in the automotive industry in Japan. In particular, since the 1990s, shot peening has been applied to many number of parts has been increasing, and it has played a major role in improving the reliability of Japanese cars.
In this talk, I report on the use of shot peening in the Japanese automobile industry from the viewpoint of materials and heat treatment. In addition, I will report on the response of shot peening process to information utilization technology such as IOT / Industry 4.0, including recent cases.
Dr. Karsten Röttger
ECOROLL AG Werkzeugtechnik
Karsten Röttger studied production engineering at RWTH Aachen University in Germany. After graduation he finished his Master thesis at the Engineering Research Center for Net Shape Manufacturing of Ohio State University in the US. Back in Germany Karsten Röttger completed his PhD at the Laboratory for Machine Tools and Production Engineering (WZL) in the area of hard turning in combination with hard roller burnishing. Since 2002 he is CEO of ECOROLL AG Werkzeugtechnik in Germany owning more than 70 patents and being the world market leader in tools for roller burnishing and deep rolling.
Abstract: Tailored Mechanical Surface Enhancement
Mechanical surface treatments, such as deep rolling or hammer peening, are capable to increase the operational safety of parts and reduce the amount of used resources. However, the process deep rolling is facing challenges driven by industrial trends, such as renewable energy, additive manufacturing, medical industry, e-mobility and industry 4.0. This presentation will give a brief overview about answers and solutions for these five highly important trends.
Renewable energy: The amount of renewable energy such as wind power is increasing all over the world. Today´s manufacturing processes for large bearings in these systems are very slow and are not improving the life endurance of the bearings. The hybrid process turn-rolling is combining the processes hard turning and deep rolling into one tool. This increases the endurance of the parts by inducing compressive residual stresses and in addition it increases the productivity of the manufacturing process.
Additive manufacturing/medical industry: The changing manufacturing chains driven by additive manufacturing processes will lead to a number of post-processing operations. Especially in the medical industry, the operational safety will be increased by deep rolling. An increase of 5.000 % and more is possible in those cases.
E-mobility: The increase of the torque by electrical engines and the important demand for lightweight structures is challenging the automotive industry. A new generation of gears will be necessary, which cannot be machined by usual processes. To increase the lifetime of this important part, a gear deep rolling process will be presented to treat the tooth and increase the fatigue life.
Industry 4.0: An innovative digital device to measure and send rolling force data into the digital world will be presented at the end of the presentation. Smart tools and processes are important to implement the mechanical process into the cloud services and digital twins in future shop floors.
Rösler Oberflächentechnik GmbH
David Soldan is Sales Manager Mass Finishing Export in Rösler. He studied business administration, and Rösler employment since 2001.
Rösler Oberflächentechnik GmbH
Sebastian Schuberth is Sales Engineer Mass Finishing Machines in Rösler. He received B.Sc. in Industrial Engineering, and Rösler employment since 2018.
Abstract: The Challenges of Finishing Additive Manufactured Parts (AM Solutions – A Brand of the Rösler Group)
Additive manufacturing (AM) is one of the key technologies to enable new possibilities in terms of design and efficiency and widen our horizon to tackle tasks that seemed impossible to reach. At the beginning of this development many supplier of this technology promoted that parts, which were manufactured additive, are directly ready to use and accomplish the same tasks as their conventional produced twins. Time and further development showed us the opposite and propositions from the past were refuted.
Next to design and geometry optimization, quality and structure of the surface figured out to be a key factor for applying AM in the industry, not only for high sophisticated parts, but also for mass production. This for post processing is mandatory to reach the requirements and evolve the entirely functional potential. For developing a high quality surface, it is not enough just to highlight the post-processing step. It is also crucial and a monetary aspect to put design phase and pre-processing into account, because the surface result is strongly affected by the layout and parameters of the AM build job, as well as the geometry.
Therefore, all steps must be coordinated with each other and the best position and orientation of the work piece needs to be found in the building space of the printer to generate as few support structures as possible. As well as the geometry must be adapted to the post processing so all major functional areas are processed and lead to a significant enhancement in surface quality, in terms of the multiple surface roughness value, fatigue life enhancement and more.
Janne Suoknuuti, is Sales Manager at Stresstech headquarter in Finland. He received his M. Sc. Physics degree from the University of Jyväskylä 2000 and worked as research scientist for nanoscience applications on low temperature in university of Jyväskylä and Cern, Geneva. Research and development scientist career continued at Stresstech for Barkhausen noise and X-ray diffraction methods. Since 2006 he has been on the sales in international market for world leading car, truck and aviation industry companies. He has got strong experience on residual stress and retained austenite measurements and grinding burn detection on research and development laboratories and production lines. Stresstech co-operates globally closely with several universities and research institutes.
Abstract: Improvement of Component Manufacturing, Durability and Failure Analysis by Quality Inspection Methods
More than 35 year of experience in quality inspection, always close relationship with world leading car, aviation industry, research institutes and universities. Stresstech has seen the development of components and changes in manufacturing processes. The environmental demands for the lower fuel consumption, easier and faster to manufacture, faster in operation etc. All these factors have been the driving force to develop lighter components. At the same time power of engine has increased which means higher demands for component quality. Small defect on the component can lead to catastrophic failure for the operating machine or even to standing component. Typically defect is caused by designing, material quality, heat treatment, machining, in-proper use or inadequate service. During the last years understanding of materials and manufacturing processes together with computer calculation capabilities has enabled to understand better complete component lifetime. Simulations for manufacturing and stresses, testing for bending, vibrations, torsion have increased understanding more the importance of good design, materials and manufacturing processes. As well new inventions have been taken to production, like new materials and additive manufacturing has shown new challenges. The modern component designing specifies more often allowed residual stress level on component surface and subsurface stresses must be controlled also. We have developed together measurement technologies together with modern industry and in our presentation we show surface integrity measurement results with Barkhausen noise, X-ray diffraction and ESPI-hole drilling.