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

The research objective of this proposal is to demonstrate feasibility of accelerating the qualification procedure described in the SAE specification AMS 4999A for alloy Ti-6Al-4V direct deposited products, as applied to the laser-based blown powder deposition process. The program vision is to design, verify and maintain control of the uncertainty in the process and to limit risk. The physics-based process modeling will be utilized in conjunction with probability theory to propagate uncertainty in the deposition process. The deposition parameters will be designed using process models and probability so as to control the uncertainty and to attain steady-state deposition. Data from the process models will be utilized with the process monitoring data in order to verify control of the key process variables as well as to identify corrective action, if necessary. Test deposits will be fabricated and CT scan data will be collected in order to verify the control of uncertainty, repeatability and predictability of the deposits.