Additively Manufactured Lightweight Aluminum Structures for Future Interceptors

The selective laser melting (SLM) of Scalmalloy is proposed for the manufacture of lightweight components on futures interceptor and kill vehicle architectures. Scalmalloy powder has been developed specifically for additive manufacturing (AM) by Airbus APWorks, and has properties that are comparable to 7075-T6 aluminum. Phase I efforts will include a trade study demonstrate that an AM Scalmalloy stage adapter can be processed at a lower cost and more quickly than a traditionally machined 7075-T6 geometry. A mass reduction task will also optimize the topology of the geometry, to allow for mass savings greater than 5%, while meeting shock, vibration, and acceleration load requirements. The proposed work also includes the build of multiple lightweighted stage adapter geometries, along with tensile, density, and surface finish samples, in order to determine the overall uncertainty of the SLM build process on the respective data samples, and to characterize dimensional consistency. The study concludes with an extensive DOE analysis to determine the sensitivity of strength, density, and surface finish to a wide range of build parameters. The study will serve as the first step in determining the optimum parameter operating space with the least variability. The heat treat process for Scalmalloy will also be optimized. Approved for Public Release | 18-MDA-9710 (6 Jul 18)