Post-Process Optimizing of Additive-Manufactured Nickel-Based Superalloys

REM has, in Phase 1, proven concept and fully developed a combinatory surface finishing process optimizing Chemical Milling and Chemically Accelerated Vibratory Finishing capable of uniformly removing .020rdquo; in less than 24 hours from the surface of Additively Manufactured (AM) Inconel-625 components, fabricated by selective laser sintering and by powder blown direct energy deposition. The as-processed components shown improved mechanical performance over the as-built components.nbsp; Building upon this 100% deliverable success in Phase 1, in Phase 2 we will: optimize processing parameters further for the Optimal Finishing Technique (OFT); conduct additional testing to validate resultant fatigue and mechanical improvements; conduct testing to validate non-reactive surface phenomenon discovered in Phase 1 during chemical milling, in which processing imparted near total IN-625 surface chemical resistance; begin processing AM IN-625 components in geometries useful to NASA and commercial parties; adapt and optimize OFT for other AM Nickel-based Superalloys (NBS) (IN-718 and AM Hastelloy-X) specimens and components;nbsp; design, build, and implement in-house OFT processing system capable of safely, cleanly, and efficiently (scalable and with minimal operator interaction) processing commercial and NASA AM components.nbsp;nbsp; Design of said in-house system will include internal neutralization tanks for reactive/toxic chemistries and scrubbers/covers for remediation of hazardous fumes such that there is no operator or environmental contact during processing.nbsp;nbsp; Ultimately, beyond Phase II, this system will be further optimized for fully scalable installation capabilities at NASA and/or customer locations to allow for processing of 100s or 1000s of components safely in situ.