Metal Additive Manufacturing to Build and Repair High-Value Copper Components

New innovations in metal additive manufacturing enable high-value components to be manufactured, repaired and prototyped quickly and cost-effectively. Arc heaters utilized by The US Air Force Hypersonic Test & Evaluation Technologies group at Arnold Engineering Development Complex (AEDC) is an example of a key asset with high-value components which are used to provide simulated test conditions and environments for a variety of vehicles. The hpersonic technology studied at the Air Force Base in Tennessee can reach incredibly high speeds, and the testing environment experiences extremely high turbulence, pressures, temperatures, and thin shock layers. These harsh arc heater conditions degrade high-value components such as electrodes and segments rapidly, both of which are primarily copper based. These current components are sole sourced, have lengthy lead times, and have unpredictable usage rates. By adapting the latest directed energy deposition (DED) technology, repairing and building these copper components can enable a return to service in a matter of days and with significant cost savings. Formalloy Technologies, Inc.'s Direct to Phase II proposal will design, manufacture, and deliver an initial system capable of repairing the damaged electrodes and segments of the arc heater, including worn areas within the inner diameter. The initial tailored system will be delivered to the customer's site by the end of the proposal and training will be provided to allow the end users at AEDC to efficiently repair an initial set of components and resume testing at their facility.