3-Dimensional, high-Z graded alloy additive manufacturing for ICBM applications

In Phase I, UTC successfully demonstrated the ability to build 3D, high-to-low-Z graded alloys (GA) with Selective laser melting (SLM) additive manufacturing (AM) techniques. In Phase II, UTC will fully automate and scale-up the GA AM process, and work with Lockheed Martin Corp. (LMCO) and Southern Research (SR) to fully characterize the process so components intended for use on LMCO missile systems can be fabricated with integrated radiation shielding. Currently, most SLM processes use a blade or roller to spread a single powder mixture across an entire layer. However, 3D GA AM requires an automated deposition system that is capable of selectively spreading multiple powder mixtures on single layers. This will be completed by integrating a dry-powder printing process into the SLM system. After UTC finishes automating this process, LMCO and SR will characterizing the resulting parts so the radiation shielding and mechanical performance can be optimized. While part characterization is ongoing UTC will begin designing a full-scale GA AM system that is capable of building full-sized parts for LMCO ICBM systems. This system, once completed and tested, will be used to build actual prototype ICBM parts with integrated shielding. These parts will be tested to confirm their shielding capability.