Methods to Enable Rapid Qualification of Additive Manufacturing Processes

ABSTRACT: Additive Manufacturing (AM) is digital/layer process for component manufacturing using automated, three-dimensional fabrication techniques, including EBAM and DMLS. Currently, AM component fabrication is costly and time consuming, using iterative and empirical Design of Experiments approach to optimize alloy selection and processing parameters. A process for rapid qualification of AM components to improve quality, reduce cost and schedule is required. Stratonics will develop a process to efficiently combine modeling and experiments that will rapidly estimate the dimensions of life-limiting defects and occurrence probability. Our innovation will use materials, processes and strength models with probabilistic consideration and in combination with processing experiments, using real-time sensing, high volume data analytics and post processing inspection. FEA simulations will be used to examine how defect size (e.g. porosity) corresponds to loaded crack propagation. The experiments will be guided by modeling and include intentional defects with a DMLS sensor suite looking for porosity event signatures with high speed/thermal imagery, multi-spectral sensory, and melt pool temperature imaging. The resulting deposits will be examined for microstructure and porosity/flaw/void, including 3D tomography and acoustic NDT. These integrated methods, model/experimental, will provide for rapid quality assessment in the early design stage, enabling damage tolerant design philosophies. BENEFIT: Aircraft engine components are increasingly being built with additive manufacturing (AM) processes and OEM"s are all active in developing AM facilities for production. Aircraft manufactures are also developing AM facilities for production. These production facilities will all use advanced model assisted experiments to efficiently and rapidly qualify materials and process parameters. The methods, models and sensors described in this proposal will address this industry need. Industry estimates that 100"s of AM equipment systems will be operation in the coming years, and numbers approaching 1000 by 2020 from Wolhers Report. These aerospace companies include GE, P & W, Rolls Royce, Honeywell, Siemens, LMCO, NGC and Boeing and others. This commercialization effort at Stratonics will involve investment, staffing and equipment production facilities. We expect to establish this manufacturing capability over the coming years, 2-3. The sales of modeling/sensor equipment will support the hiring of engineers, technicians and documentation specialists at Stratonics.