Innovative Approach to Rapidly Qualify Ti-6Al-4V Metallic Aircraft Parts Manufactured by Additive Manufacturing (AM) Techniques

MER will implement closed loop process control of its high rate Plasma Transfer Arc (PTA) additive manufacturing system primarily for use with high rate Ti-6-4 wire deposition (>20 lb. Ti-6-4 /hr.) and also for powder feeds. Use of an ICMSE process model developed by Applied optimization (AO) in Phase I will provide the basis of closed loop control by guiding the build torch power setting by comparing measured sensor data for local melt pool temperature with that predicted by the model for defect free builds and controlled and uniform microstructure. In addition to implementing the closed loop process control, MER will evaluate use of mid IR temperature mapping of the melt pool to identify random processing defects and allow for their mitigation and removal by resurfacing and insitu machining. For mechanical property management of the build, Questek will provide the framework for a microstructural vs mechanical property physics based model so that a microstructurally controlled and defect free deposit can be produced with predictable mechanical properties to allow accelerated qualification of Ti-6-4 PTA AM parts