Additive Manufacturing of TZM Refractory Metals for Hypersonic Thermal Management Structures

ExOne successfully demonstrated the feasibility of using additive manufacturing to produce TZM refractory alloys at full theoretical density for hypersonic thermal protection / management / structures and met all of the Phase I research objectives. The process was developed beginning with a thorough powder feedstock characterization, followed by printing process parameter development, and finally with sinter and Hot Isostatic Pressing (HIP) densification process development. ExOne was able to achieve theoretical density TZM (10.2 g/cc) material and produced numerous coupons that were used for material characterization. Finally, ExOne designed, printed, and densified a subcomponent, complex, application relevant geometry in TZM alloy to prove feasibility of making complex shaped structures. At the end of the Phase II program – ExOne will deliver a manufacturing demonstration article that is additively manufactured in TZM material in a geometry relevant to hypersonic thermal structures. ExOne will deliver a material property data set that will be used in future design efforts. Optimized printing and sinter / HIP processes will be defined. ExOne will have additively manufactured TZM capabilities ready for consideration in technology insertion /qualification for hypersonic weapon platforms. At the end of the Phase II program – ExOne will deliver a manufacturing demonstration article that is additively manufactured in TZM material in a geometry relevant to hypersonic thermal structures. ExOne will deliver a material property data set that will be used in future design efforts. Optimized printing and sinter / HIP processes will be defined. ExOne will have additively manufactured TZM capabilities ready for consideration in technology insertion /qualification for hypersonic weapon platforms. Approved for Public Release | 20-MDA-10643 (3 Dec 20)