Qualification Of Additive Manufacturing Processes And Materials In .

Transformative Aeronautics Concepts ProgramDevelopment of an Additive Manufacturing Ecosystem forQualification of Additive Manufacturing Processes and Materials inAviationActive Technology Project (2019 - 2022)Project IntroductionThe major challenges associated with additive manufacturing (AM) are anability to qualify parts and the costs associated with the technology. Our teamwill study and mature technologies as detailed below to develop an ecosystemfor the qualification of AM machines, which in turn supports the certification ofpart production.Additive manufacturing offers unique opportunities for the aviation industry inthe fabrication of original components and replacement parts. Aggressive useof metals AM has, for example, allowed the rapid development and productionof new launch vehicle designs, at substantially reduced costs. Aviation hasunique challenges, such as higher production volumes, but the potential valueof integrating AM into aviation manufacturing is clear.To implement the ecosystem for AM qualification, the team will run a set of sixmulti-disciplinary projects. Each of these projects will address a current barrierto AM process qualification, and efficient production.The figure shows an example ofhow the defect structure in laserpowder bed fusion machinesvaries in a systematic but highlynon-linear manner acrosspower-speed space. In onecorner, lack of overlap of meltpools induces lack-of-fusion Table of ContentsProject IntroductionOrganizational ResponsibilityProject ManagementAnticipated BenefitsPrimary U.S. Work Locationsand Key PartnersTechnology Maturity (TRL)Technology AreasTarget DestinationSupported Mission TypeImagesLinksPrinted on 01/05/202105:28 PM PSTFor more information and an accessible alternative, please copy12233333355Page 1

Transformative Aeronautics Concepts ProgramDevelopment of an Additive Manufacturing Ecosystem forQualification of Additive Manufacturing Processes and Materials inAviationActive Technology Project (2019 - 2022)1. AM Flaw Management: Flaw (dominated by pore structure)management is currently the most important need in thefabrication of aviation components subjected to fatigue. Thisproject will define the processing window to achieve flaw/porositycontrol within defined limits and further demonstrate how processoptimization can control porosity levels within that processingwindow. Mechanical properties such as fatigue will be used toquantify the effects of porosity and build the necessary dataportfolio for process qualification.2. Qualification Aware Process Maps: There is a concern in the aeroindustry that any changes in process variables require a full requalification of an AM process and this is leading to qualificationefforts focusing on a single process variable set (usually defined bya machine manufacturer). This project will address this concern bydefining multiple process variable points within the process window(Project #1) and developing data for each of them for qualification.3. Qualification Aware Post Processing: Post processing of an aviationpart can easily cost as much as the additive fabrication itself, yetlittle science has been applied to post processing of AM parts. Inparticular, there is an important coupled relationship between AMprocessing and post processing to achieve optimal cost andperformance. This project will investigate and implement moreefficient post-processing methods that support qualification.4. Database Analytics: This project will compile data from allmembers on process-structure- property relationships, with a focuson porosity and fatigue. This project will apply data science todevelop a model for qualification that will be used in training andeducation (next project).5. Training and Education: We will disseminate project results acrossUniversity, Small Business and Partner Company and GovernmentLaboratory team members and will train small businesses lookingto become Tier 1 AM suppliers. Dissemination will occur throughstudent and industry employee exchanges executed at theacademic team member sites. We will also train potential AMcomponent suppliers (subcontractors) to achieve various definedlevels (tiers) of AM expertise and thus qualify their processes usingthe results of these projects.6. Scaling to Production: A critical barrier to widespread use of AM inaviation manufacturing is the scaling from research-basedcomponent fabrication to small-scale production at the rate ofhundreds or thousands of parts per year. This project willinvestigate optimal configurations of combined pre-processing,processing and post-processing cells that exploit roboticautomation and its integration with human workers.Printed on 01/05/202105:28 PM PSTOrganizationalResponsibilityResponsible MissionDirectorate:Aeronautics Research MissionDirectorate (ARMD)Lead Organization:Carnegie Mellon UniversityResponsible Program:Transformative AeronauticsConcepts ProgramProject ManagementProgram Director:John A CavolowskyProject Manager:Koushik DattaPrincipal Investigator:Anthony D RollettCo-Investigators:Jack BeuthErica FuchsElizabeth HolmKenji ShimadaJohn LewandowskiOwen HildrethAlbert ToRyan B WickerSneha P NarraJohn BarnesAyman SalemCraig A BriceFor more information and an accessible alternative, please copyPage 2

Transformative Aeronautics Concepts ProgramDevelopment of an Additive Manufacturing Ecosystem forQualification of Additive Manufacturing Processes and Materials inAviationActive Technology Project (2019 - 2022)Anticipated BenefitsOver the last eight years, metals Additive Manufacturing (AM) has impactedaviation manufacturing for jet engine components, airframe structuralelements, and other applications. Looking ahead, AM is likely to substantiallyimpact the desired outcomes for aviation manufacturing identified by NASA forthis project. Accordingly, the over-arching project goal is the demonstratedestablishment of an ecosystem for qualification of powder bed additivemanufacturing processes that is based on flaw management. Solving thetechnical challenges and disseminating the qualification protocol to companies,especially Tier 1 suppliers and below will move aviation manufacturing towardsachieving NASA Aeronautics Research Mission Directorate's objectives forinnovative solutions that reduce time-to-production, improved process control,and product tailoring. The successful implementation of the proposedqualification framework for AM powder bed should substantially advance U.S.manufacturing capabilities in terms of flexibility of design, time-to-market etc.It will also bring down the cost of manufacture particularly for short productionrun parts and replacement parts. Economic growth will be boosted,particularly through enabling small contractors who lack access to Researchand Development depth to qualify their AM processes and equipment and keepthem qualified over time. Interaction with large original equipmentmanufacturers has indicated that most of them plan to eventually subcontractmuch of their AM fabrication work to small AM contractors. As small suppliersgain confidence in their ability to produce qualified parts, they will addmachines and people to increase production.Technology Maturity(TRL)Start:2Current:2Estimated End: 4123AppliedResearch456Development789Demo & TestTechnology AreasPrimary:TX12 Materials, Structures,Mechanical Systems, andManufacturingTX12.4 ManufacturingTX12.4.2 IntelligentIntegratedManufacturingPrimary U.S. Work Locations and Key PartnersTarget DestinationFoundational KnowledgeSupported MissionTypePushPrinted on 01/05/202105:28 PM PSTFor more information and an accessible alternative, please copyPage 3

Transformative Aeronautics Concepts ProgramDevelopment of an Additive Manufacturing Ecosystem forQualification of Additive Manufacturing Processes and Materials inAviationActive Technology Project (2019 - 2022)Organizations Performing WorkRoleTypeLocationCarnegie Mellon UniversityLead OrganizationAcademicPittsburgh, PABarnes Global AdvisorsSupporting OrganizationIndustryPittsburgh, PACase Western Reserve UniversitySupporting OrganizationAcademicCleveland, OHColorado School of MinesSupporting OrganizationAcademicGolden, COMaterials Resources LLCSupporting OrganizationIndustryDayton, OHUniversity of PittsburghSupporting OrganizationAcademicPittsburgh, PAUniversity of Texas at El PasoSupporting OrganizationAcademicEl Paso, TXWorcester Polytechnic InstituteSupporting OrganizationAcademicWorcester, MAPrimary U.S. Work sPrinted on 01/05/202105:28 PM PSTFor more information and an accessible alternative, please copyPage 4

Transformative Aeronautics Concepts ProgramDevelopment of an Additive Manufacturing Ecosystem forQualification of Additive Manufacturing Processes and Materials inAviationActive Technology Project (2019 - 2022)ImagesProcess window defined bydefect typeThe figure shows an example ofhow the defect structure in laserpowder bed fusion machines variesin a systematic but highly nonlinear manner across power-speedspace. In one corner, lack ofoverlap of melt pools induces lackof-fusion porosity. In the oppositecorner, excessive keyhole depthresults in instability and keyholeporosity. In between these twolimits there is a region of highdensity that nevertheless can bedisrupted if the combination of highspeed & power results in too-longmelt pools and the bead-upproblem. Inside these limits thereis a process window within whichone expect within which one expectnear full ksA Comprehensive Comparison of the Analytical and Numerical Prediction of the Thermal History and SolidificationMicrostructure o(https://doi.org/10.1016/J.ENG.2017.05.023)A Process Map for Consistent Build Conditions in the Solid Freeform Fabrication of Thin-Walled ed on 01/05/202105:28 PM PSTFor more information and an accessible alternative, please copyPage 5

Transformative Aeronautics Concepts ProgramDevelopment of an Additive Manufacturing Ecosystem forQualification of Additive Manufacturing Processes and Materials inAviationActive Technology Project (2019 - 2022)An Investigation of Process Parameter Modifications on Additively Manufactured Inconel 718 alyzing the effects of powder and post-processing on porosity and properties of electron beam melted 40911)Anomaly detection and classification in a laser powder bed additive manufacturing process using a trained computervision )Characterization of metal additive manufacturing surfaces using synchrotron X-ray CT and micromechanical )Computer Vision and Machine Learning for Autonomous Characterization of AM Powder -1)Critical instability at moving keyhole tip generates porosity in laser /6520/1080)Defect Structure Process Maps for Laser Powder Bed Fusion Additive -dictated tensile properties of selective laser melted .004)Effect of Laser-Matter Interaction on Molten Pool Flow and Keyhole .064054)Evaluating the Effect of Processing Parameters on Porosity in Electron Beam Melted Ti-6Al-4V via Synchrotron 015-1802-0)Evaluation of Orientation Dependence of Fracture Toughness and Fatigue Crack Propagation Behavior of As-DepositedARCAM -speed Synchrotron X-ray Imaging of Laser Powder Bed Fusion 280)Keyhole threshold and morphology in laser melting revealed by ultrahigh-speed x-ray yhole Threshold and Morphology in Laser Scanning Melting Revealed by Ultrahigh-Speed X-ray cation specific solidification microstructure control in electron beam melting of 003)Measurement and Analysis of Porosity in Al-10Si-1Mg Components Additively Manufactured by Selective Laser d on 01/05/202105:28 PM PSTFor more information and an accessible alternative, please copyPage 6