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Additive Manufacturing at Lockheed Martin
Hank PhelpsSr Staff M&P EngineerLockheed Martin Aeronautics
additivemanufacturingseries.com
© 2019 Lockheed Martin Corporation. All Rights Reserved. Approved for Public Release AER201709030 & AER201801020
Introduction
• Overview of Lockheed Martin• Business Unit Structure
• AM Capabilities Across LM
• LM AM Deployments
• Highlights of AM Development Done for Fighter Application
• Summary
Lockheed Martin at a Glance
Lockheed Martin Business Areas
LM Additive Manufacturing Capabilities
• Small Polymer• Fused deposition modeling for thermoplastics • Stereolithography • Other technologies
• Large Polymer• 2-robot cluster for carbon-reinforced ABS • Big Area Additive Manufacturing (BAAM) system for thermoplastics
• Small/Medium Metal• Electron beam powder bed for titanium • Laser powder bed for aluminum, titanium, & steel
• Large Metal• Electron beam wire-fed for all Titanium/Inconel• Wire-Arc Additive Manufacturing (WAAM) for steel and aluminum
• Advanced Materials• Aerosol jet for nanomaterial applications
LM Deployed Additive Manufactured HW
F-16 Drag Chute Frame
Background
• The F-16 Drag Chute Frame• Aft End of Canister that holds the Drag Chute for Short Field Landings
• Currently an A357 Casting• Issues with getting timely delivery
• Quality issues impacting fit-up and assembly
• Canister supplier requested a re-design to eliminate casting
• Evaluated Laser-Powder Bed Fusion (L-PBF) Alternative• Fabricated 6 Proof-of-Concept Parts at 3 Different Vendors
• Generated Preliminary Property Data
Proof-of-Concept Builds
Machines Used E0S M280, SLM 280 and Concept Laser X1000
Thermal Treatment Selection
A357-T61 Spec Min Values w/o Casting Factor Ult=50 ksi Yld=40 ksi
• Difficulty Meeting Properties with Typical HT
• Lower Temperature SR Had Competitive Properties
Mechanical Property Evaluation
Chemistry
AX4-CHM-XZ-1 AX6-CHM-XZ-1 Min % Max %
Si 10.23 10.45 10.48 9.00 11.00
Fe 0.18 0.19 0.21 0.55
Cu 0.01 0.01 < 0.01 < 0.05
Mn 0.01 0.01 0.01 0.10
Mg 0.35 0.28 0.31 0.25 0.45
Ni 0.01 0.01 0.01 0.05
Zn 0.01 < 0.01 < 0.01 < 0.10
Ti 0.01 0.01 0.01 0.15
Pb .01 < 0.01 < 0.01 < 0.02
OT 0.15 < 0.10 < 0.10 < 0.15
OE 0.05 < 0.05 < 0.05 < 0.05
Al Balance Balance Balance
Powder CertDeposited Samples LMA-PA002 Req
Balance
Element
Density & Porosity
Microstructure
Looking Down on XY Plane
Perpendicular to Z Axis
Tensile Properties
Typical Stress vs Strain Curves
Compression Yield Strength
Bearing StrengthE/D = 2.0
Izod Impact Strength
JIC Results
Specimen Orientation JIC
AX8-J1C-XZ-1 XZ 26.4
AX8-J1C-XZ-2 23.2
AY4-J1C-YZ-1 YZ 27.4
AY4-J1C-YZ-2 24.6
AX8-J1C-ZX-1 ZX 15.9
AX8-J1C-ZX-2 21.1
SN Fatigue
AlSi10Mg
A357-T61
Static Data
Compression
Data
IZOD Impact
DataJIC
ASTM E111 ASTM E9 ASTM E23 ASTM E1820
TUS (ksi) TYS (ksi) e (%) RA (%) Mod (Msi) CYS (ksi)BUS
(ksi)
BYS
(ksi)
Impact Str
(ft-lbs)
Toughness
(ksi-RtIn)
X 56.1 34.9 8.8 11.4 10.8 31.1 98.4 81.3 XZ = 22.7 XZ = 24.8
Y 55.8 35.2 8.6 10.8 10.9 31.0 100.3 86.3 YZ = 23.7 YZ = 26.0
Z 60.7 31.6 5.3 8.1 10.4 36.6 99.2 84.1 ZX = 14.7 ZX = 18.5
ASTM E8 ASTM E 238
Orientation
Tensile DataBearing Data
(e/D=2.0)
Observations
• Tensile ultimate highest in Z but yield, e & RA lowest in that direction compared to X or Y
• Compression yield strength was highest in the Z direction while the X & Y results were comparable
• Bearing ultimate strength was relatively insensitive to specimen orientation
• Impact strength was comparable when impacting across the X or Y directions while across the Z direction had lowest impact strength (36% lower than X & Y)
• Fatigue results comparable for all orientations tested
Comparison of AM vs Casting Values
Conclusion
• AM AlSi10Mg is a Viable Alternative for Aluminum Castings• Not a drop-in replacement
• Some properties lower than castings• Fty, Fcy and Bearing
• Best Near Term Uses• Non-critical applications
• Complex geometries (difficult to machine)
• Size compatible with existing AM machines
• Short run &/or quick turn applications
QUESTIONS