Fabrication Process for Small, High-precision Aerodynamic Balances

ABSTRACT: The proposed research seeks to establish DMLS as a process in which 15-5 PH powder can be used to grow an aerodynamic balance with the appropriate material properties, geometric tolerances, and surface finish required. Phase I will be focused on developing DMLS manufactured parts with external features representative of current and future aerodynamic balance design as well as demonstrate homogeneity and similarity to the material properties of 15-5 PH. The approach in Phase I will be to establish the feasibility of the metal alloying process of the material formation and demonstrate the resolution of the formation process. BENEFIT: Determination of the viability for the development of DMLS scanning parameters producing; optimal surface finish, porosity and absence of micro or macro cracking. A report summarizing metallurgical findings that establish the feasibility of 15-5 PH SS as a DMLS alloy meeting industry engineering standards. Representative parts summarizing the achievable dimensional tolerances.