Development and Qualification of Large AA7XXX Replacements via Solid-State and Lubricant-Free Additive Manufacturing

Solvus Global as the leading small business is forming a multi-discipline team including Baylor University (STTR RI) and Bond Technologies. The Solvus-Baylor-Bond team proposes two approaches to achieve 1-to-1 AM of large AA7XXX components by the upgraded AFSD-round feedstock (AFSD-RF) and the active-cooling tool for the conventional AFSD. The first approach of the upgraded AFSD-RF utilizes round-off set feedstock. The AFSD-RF has successfully deposited AA7XXX and does not require graphite lubricant compared to the previous AFSD square center-fed design. In addition, the upgraded ASFD-RF uses more economical extruded round feedstock instead of the laborious machined square-rod feedstock in the previous design Ā. ĀConcurrently, Solvus Global will oversee the second approach of developing an active-cooling AFSD tool to constrain the thermal expansion of the feedstock and avoid graphite lubricant. Both Solvus and Baylor will perform their work using the ASFD machines manufactured by Bond, which will provide system updates and improvement to Solvus and Baylor during the program. Upon completion of the Phase I project, the Solvus-Baylor-Bond team will deliver:Ā 1.ĀĀ ĀUpdated AFSD process-structure-property framework to facilitate future process optimization and qualification 2.ĀĀ ĀImproved AFSD process and machine system for printing large AA7l49 components as representative AA7XXX 3.ĀĀ ĀA full-sized near net shape component with geometries provided by Army using the improved process and system, exhibiting lack of defects and promising mechanical properties as Phase I feasibility demonstration.