Electron-Beam Additive Manufacturing Process Control for Titanium Alloys

Electron Beam Free Form Fabrication has the potential to produce large titanium structures directly from 3D models eliminating or reducing the long lead times associated with designing, procuring, and implementing conventional forging tooling as well as reducing the amount of machining cost by producing near net shapes. Our proposal outlines an approach to demonstrate the use of this technology such that it meets or exceeds the target goal of a manufacturing readiness level of 4. This shall be demonstrated by combining our core competency in the field of CNC controlled electron beam systems and ongoing process control refinement with strategic partnerships with industry experts in the titanium aero structures community. We will be directing our efforts such that EBFFF/EBAM becomes an established process meeting both DoD and commercial aerospace requirements. Utilizing our in house EBFFF capabilities we have become an industry leader in this technology and through existing and ongoing industry relationships we are continually adding improved process controls and sensors directed at providing high quality and repeatable deposits targeting a robust processing system intended to transition into a viable supply base to support both military and commercial entities. BENEFITS: Benefits of commercializing this technology include reduced lead times and cost compared to conventional forgings. As the technology becomes accepted, incorporating the concepts of EBFFF/EBAM will allow greater flexibility for the designers, and new markets for our electron beam deposition systems. As the process is proven and accepted by Air Force and Commercial end users, existing "parts supplier" subcontractors are anticipated to rapidly add this capability growing the supply base and most likely through increasing competition the end users will see additional cost reductions.