Additive Manufacturing of Advanced Metallics

The Missile Defense Agency is seeking innovative material and manufacturing processes for advanced metallic components for hypersonic flight systems. Triton Systems and their academic partner are proposing to develop the manufacturing and qualification evaluation techniques for reliable production of hypersonic environment appropriate metallic components at reduced cost and timelines compared to traditional fabrication methods (casting or forging). Evaluation techniques will include thermal (thermal expansion, conductivity, and specific heat) analysis and mechanical (strength, flexural) for additively manufactured (AM) metallic parts using appropriate alloys. Results from AM samples will be compared to those of casting or forging equivalents. Analysis will be performed over appropriate temperature ranges for the hypersonic environments. During Phase II, the Triton team will demonstrate the advances from Phase I to produce subscale coupons for laboratory and ground testing. Testing will include hypersonic relevant environment testing and analysis. Statistical analysis for repeatability/quality of the materials fabricated using the chosen AM process will also be performed. A preliminary cost and schedule analysis comparing the AM process and materials to current state-of-the-art processes will also be developed. Approved for Public Release | 22-MDA-11339 (13 Dec 22)