don’t melt. meld.€¦ · 2019 gold winner appliedtechnology ... composites al-sic, al-fe, al-w,...

Don’t melt. MELD.

MELD: How it works

June 26, 2019 This document is proprietary and the property of MELD Manufacturing Corporation. All Rights Reserved. 3

The MELD tool and feedstock material are rotated while applying downward forces resulting in the plastic deformation and subsequent deposition of the feedstock material.

either

solid bar

powder(s)

MELD is more that AM

June 26, 2019 This document is proprietary and the property of MELD Manufacturing. All Rights Reserved. 4

MELD is a solid-state additive manufacturing method for AM manufactured components, printing metal onto existingstructures/applications, repair, coating, and joining similar and dissimilar metals and metal matrix composites.

Unique value proposition: MELD yields a metallurgical bond between the deposited material and substrate, as well as between subsequent deposited layers

ADDITIVE MANUFACTURING

Make high quality near net shape parts at a high production

rate.

JOINING

Join same or dissimilar materials.

SECONDARY PROCESS

Open up primary

manufacturing options by

adding features after.

COATINGS

Protect parts with wear resistant

coatings that will not

delaminate.

REPAIR

Repair even unweldable

metals – from casting defects to equipment in the field.

Comparison to other Metal Process Options

June 26, 2019 This document is proprietary and the property of Aeroprobe Corporation. All Rights Reserved. 5

AFS OTHERS PROCESS CONSIDERATIONS IMPACT

✓ POWER COST✓ BUILD SIZE FEASIBILITY✓ MATERIAL REQUIREMENTS COST, FEASIBILITY✓ SECONDAY PROCESSING COST, QUALITY✓ ATMOSPHERIC SHIELDING COST, QUALITY✓ BUILD SPEED COST, FEASIBILITY✓ QUALITY FEASIBILITY

✓ PART COMPLEXITY COST, FEASIBILITY✓ MACHINE PRICE AND OPERATING COST COST

MELD

Proven Technology from a Woman-Owned Small Business

13

patents

issued

and

patents

pending

Our experienced, passionate team has successfully developed MELD from concept to a mature process that is well positioned to bring an immediate and impactful benefit to Industry. We

can enable the use of advanced materials, improve logistics, and bring revolutionary

technology to you.

Come visit us in Virginia!

Award Winning Technology

This document is proprietary and the property of MELD Manufacturing. All Rights Reserved. June 26, 20197

2018 WINNER

SAE TECH BRIEFS

Expeditionary Technology Search FINALIST

2019 GOLD WINNERApplied Technology - Clean Manufacturing

Use the alloys you prefer with MELD


Stainless Steel: 316L

Nickel Alloys: IN625

Aluminum: Al2139

100 µm 100 µm

500 µm 50 µm

25 µm25 µm

50 µm 50 µm

Material Family Demonstrated with MELD

Aluminum 1XXX, 2XXX, 5XXX, 6XXX, 7XXX

Magnesium AZ31, AZ91, WE43, E675, AMX602, E21

Copper Cu 110, NAB

Titanium Ti64, Titanium Aluminide

SteelODS 14YWT-F82H, 300M-4140, Aermet

100-4140, A514

NickelInconel 625, Inconel 718, Inconel 600, Cu-

Ni200, Nimonic 80A

Metal Matrix

Composites

Al-SiC, Al-Fe, Al-W, Al-Mo, Al-BNC, Al-CF, Al-

CNT, Cu-W, Cu-Ta

Al 20 lbs/hr Steel 10.7 lbs/hr Ti 5.5 lbs/hr Ni 1.5 lbs/hr

Titanium: Ti64

Why MELD – Not Restricted to AM Materials

This document is proprietary and the property of MELD Manufacturing. All Rights Reserved. June 26, 2019 9

2018

0

5

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15

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25

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45

50

0

100

200

300

400

500

Cast AlSi10Mg DMLS F357 DMLS AlSi10Mg MELD Al7075 MELD Al2219

MP

a

Tensile Strength Yield Strength % Elongation

MELDOpen Source Materials and Parameters

*Source: 03/15/2018: Light Metal Age

MELD after solution/aging DMLS after HIP/Heat Treat*Cast

https://www.lightmetalage.com/news/industry-news/3d-printing/article-additive-manufacturing-of-aluminum-alloys/

Why MELD – Better Quality

OTHER PROCESSES MELD


2018MELD non-melt technology prints better quality parts with minimal residual stress

Residual stress introduced by EBAM deposition warps a 0.75” steel plate

Residual stress leads to catastrophic cracking and delamination of the part or distortion of the build plate

MELD residual stress in a 0.08” aluminum plate with minimal distortion

EBAM ~ 6” x 5” x 0.5” MELD ~ 8” x 10” x 2”

Source: Published Papers on Residual Stress of AM Parts

DMLS

Examples of MELD Use


MELD Repair of Cast Mg Gearbox Housing


Cast AZ91 Magnesium helicopter

gear box rib fracture previously

unrepairable due to non-fusion

weldable properties of Mg. MELDenables the opportunity to repair

otherwise unrepairable damage

of high-cost components.

MELD Missile Launcher Rail Repair


Al7075 missile launcher rail failure due to wear caused

by continuous vibration during flight. Other repair

methods were not successful due to non-fusion

weldable alloy and inaccessibility of the worn surfaces.

Al7075 Missile Launcher Rails

location of worn surfaces

MELD Repair of Armor-Grade Aluminum Alloys


as-received Al2024 MELDed Al2024

The MELD process is a portable, fieldable method suited for the repair and joining

of non-fusion weldable aluminum alloys. It has been demonstrated that a mobile

MELD platform could be implemented to perform joining and repair operations in a

FOB environment.

fully dense material better than wrought repeatable portable robust

16

MELD Ballistics Repair:Damaged plate

MELD Ballistics Repair:MELDed plate

MELD Ballistics Repair:Machined plate

MELD Inconel 625 Shaft (HY80) Coating


IN625 coatings applied via the MELD process exhibit

metallurgical bonding to the HY80 shaft material,

equiaxed/refined microstructure, and significantly

better-than-wrought mechanical properties.

MELD – Inconel 625 Data

Better Tensile Properties = Better Quality Production Parts


2018MELD IN625 “as-deposited” has superior YS and UTS compared to alternate technologies

Source: University of Alabama Research Paper

June 26, 2019

MELD Deposition of IN625 onto HY80 Steel

BENDING TEST

In 625

In 625

HY 80

In 625

HY 80

In 625

In 625100µm

100µm

100µm

No delamination and cracking →defect-free, metallurgically bonded interface.

22This document is proprietary and the property of MELD Manufacturing. All Rights Reserved.

MELD Coating Comparison


Thermal spray Inconel 625coating

(A.A. Boudi et. Al., Journal of Materials Processing Technology 155–156 (2004) 2051–2055)

Cold-spray Inconel 625coating

(P. Poza, et al., Surface & Coatings Technology (2012), Doi:10.1016/j.surfcoat.2012.03.018)

MELD Inconel 625 coating

No voids, oxides, contaminants No post=processing required

HIP or other

Porous and other bonding issuesw/secondary post-processing

requiredSizeable surface preparation

required for both cold-spray and thermal spray

No surface preparationrequired (typical)

NSWCCD Wear Test

June 26, 2019 This document is proprietary and the property of Aeroprobe Corporation. All Rights Reserved. 24

Test parametersMethod : Kommers Abrasive Wear Testing conducted at NSWCCD Bearing material : 1x1x1” cube of HY80 with 2mm thick MELD depositJournal material :2 1/8” Journal, of bearing material Contact load : 1.76lbAbrasive used : Heavy Grit, 54 size brown Aluminum Oxide Environment : Fresh Water Rotation speed: 97rpm

MELD IN625 Wear Testing Results


Sample no.

Mass loss: MELDcoated Inconel 625

(g/h)

Mass loss:Romor journal

(g/h)

1 0.092 0.063 0.08

Average 0.076 0.07

Sample no.

Mass loss: Cast Inconel 625 (g/h)

Mass loss: Romorjournal (g/h)

1 0.131 0.05

Sample no.

Mass loss ESS Clad Inconel 625 (g/h)

Mass loss: Romorjournal (g/h)

1 0.118 0.0625

The initial wear testing results show that MELD deposited Inconel 625 showed 35% and 41% lower wear than clad and cast Inconel 625,

respectively.

MELD Coating Cast Clad

MELD IN625 Fatigue Results


MELD IN625 was seen to have upwards of 4X the cycles to failure compared to the IN625 bar stock.

The increase in fatigue life is contributed the dense refined granular microstructure observed within the MELD process.

MELD

MELD Ti64 Tensile Data


As-Received Ti64

As-Deposited Ti64

MELD Nickel Aluminum Bronze: Repair and AM


MELD is a successfully demonstrated method for the repair and additive manufacture of NAB

Cast NAB MELDed NAB


MELD has extreme capability for

emergency field repair to achieve

immediate survivability.

As a demonstration, this component with

extreme loss of non-fusion weldable

material was repaired with no surface

preparation at all. Repair was done in open

atmosphere.

MELD repaired the part, making it workable

immediately, with sufficient bond strength

between added material and existing

material to ensure structural integrity. The

surface finish is near net, good enough to

put back in the field if needed.

MELD Repair-Nickel Aluminum Bronze (NAB)

June 26, 2019 Proprietary information of Aeroprobe Corporation 30


FRACTURE LOCATION

BEND TESTING

Wear-resistant refractory

coating application for

enhanced performance

MELD Coating Rail Gun Rails with Refractory Materials

MELD – Printing AM Components

Lower Cost, Faster Production, Better Quality, Choose Your Metal


2018MELD prints AM parts with lower cost raw materials, faster deposition rates, better mechanical

properties, eliminates post processing costs, and you select the material

Cu110 Rocket NozzleLower raw material cost, no post HIP/VF costsFaster: Deposition rate 14 lbs/hr and near-netChose your metal: Who offers Copper?Better Quality: Outstanding mechanical properties

Al6061 Pressure Vessel DomeLower raw material cost, no post HIP/VF costsFaster: Print time 2 hours and near-netChose your metal: Who offers Al6061?Better Quality: Outstanding mechanical properties

Mg675 Army Picatinny RailLower raw material cost, no post HIP/VF costsFaster: Near-netChose your metal: Who offers Magnesium?Better Quality: Outstanding mechanical properties

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Number of layers: 46 (12 layers/in)

Deposition time: 6.5h

Window frame

demonstration

article for Orion

Crew Module

MELD Adding Features: Window Frame

13” X 11” X 3.5”


MELD Adding Features: Rib Structures

Al2139 Rib Deposit

Scale: 50 µm

Scale: 500 µm

as-received Al2139

MELDed Al2139

2219 test sample would be acceptable per ASTM B594-13, Immersion, Class A requirements for wrought aluminum products.

Ribs and Features: Finished Part


Reducing Fixtures and Bolts on Thin Wall


MELD was used to replace a traditional

cross-member to rail attachment, providing

advantages:

Reduces number of bolts used

Increases strength

Eliminates corrosion jacking of the support

Better distributes stress shown here:

Building Pockets



Battlefield Scrap Recycling: Powder to Chip

Demonstrating the ability to use AL 5083machining chips (2-3 mm) as feed stock for MELD“powder” system

US ARMY DEVCOM PROJECT EXCERPT

Demonstration of Repair Using Battlefield Scrap


Approved for public release

Approved for public release

U.S. ARMY COMBAT CAPABILITIES DEVELOPMENT COMMAND –ARMY RESEARCH LABORATORY

ØPresented by: ØMarc Pepi (Materials Engineer, CCDC – ARL), and Nanci Hardwick (CEO, MELDTM Manufacturing)

ØProgress Towards Expeditionary Production of AM-Grade Metallic Powder and Subsequent Additive Manufacturing Applications

ØDISTRIBUTION A: Approved for public release;

distribution is unlimited

ØContributing authors:

ØJennifer Sietins (CCDC – ARL), Chase Cox (MELDTM Manufacturing), R. Joey Griffiths (VA Tech), Hang Z. Yu (VA Tech), Chris Eonta (MolyWorks Corp.), Andrew LaTour (MolyWorks Corp.), Matthew Charles (MolyWorks Corp.), Danielle Cote (WPI), and Jessica Sun (Bennett Engineering)

Progress Towards Expeditionary Production of AM-Grade Metallic Powder and Subsequent Additive Manufacturing Applications

Minimal Penetration of .45 ACP+P

Optical image of aluminum powder produced by MolyWorks entirely from battlefield scrap. Geometry and diameters of particles appear optimal for AM processes (scale bar = 50µm).

MolyWorks powder from scrap aluminum: Chemical Analysis:

ElementMolyWorks

Aluminum from Scrap (wt%)

Casting Alloy AA355

(nominal wt%)Aluminum Balance Balance

Oxygen 0.096

Nitrogen 0.001

Carbon 0.015

Sulfur <0.001

Iron 0.98 <0.6

Silicon 4.93 5.0

Magnesium 0.75 0.5

Manganese 0.29

Copper 1.47 1.25

Gallium 0.012

Nickel 0.018

Lead 0.037

Tin 0.014

Titanium 0.11

Zinc 0.095 <0.35


Minimal Penetration of .45 ACP+P

MolyWorks Powder: Aluminum – all scrap

Laser DiffractionBeckman Coulter

LS 13 320 SW7gms

UCF particle-size distribution of MolyWorks Mobile Foundry powders

<10% <25% <50% <75% <90%

10.73µm 18.58µm 27.53µm 35.67µm 42.64µm

Volume Statistics

ALL powder sizes were used in MELD deposition. No sieving was required.


MELDTM Additive Friction Stir (Component Repair):Objective

• Proof-of-concept of utilizing AFS with MolyWorks powder from scrap aluminum for repair applications.

Approach• AFS deposits powder over simulated

damage.• Metallography, and CT was used to

characterize depositPartners

• Nanci Hardwick, and Chase Cox, MELD Manufacturing Corporation; Joey Griffiths, and Hang Yu, VA Tech University.


Panel after excess aluminum deposited by AFS was milled down, showing area of repair.

Computed tomography (CT) cross section of panel.

Examples of MELD Machines


MELD Machines


•Table Size: 42” x 18”•Build Volume: 36” x 12” x 12”•Overall Dimensions: 120” x 132” x 132”

Machine Specifications

MELD model B8 is an open atmosphere, 3-Axis CNCmilling machine style platform with an easily scalablegantry system for larger parts. Localized gas shieldingis available for sensitive materials.

3 ft3 82 ft3 266 ft3

Portability: Conex Shipment and Use


FOR FIELD USE:

• Use indigenous materials,

including waste streams.

• Increase safety with dolid metal

instead of powder.

• MELD does not require lasers or

gases.

• Lower power

• Builds/Repair survive loss of

power

• Easy to train users

• Robust process can tolerate no

surface preparation for repair

Portability: Shipyard Repair


In Theater


Advantages of MELD Metal AM Technology


1 STEP: No melting means fully-dense material. Skip the time and cost of HIP/Vacuum Furnace/Sintering

LOW STRESS: No melting means less heat, which means less residual stress, which means less distortion

FAST: Scalable technology supporting large-size AM applications with fast deposition rates (Al > 20 lbs/hour)

VERSATILE: Superior coating technology compared to cold-spray, thermal-spray, PPAD, and electro slag surfacing

QUALITY: MELDed material avoids the pitfalls of melt-based processes (no porosity, hot-cracking, segregation, or dilution)

FREEDOM: Use your own materials. Use it to make new alloys, metal matrix composites, and more.

Advantages for Repair


• MELDed material exhibits exceptional mechanical properties (near-wrought or better)

• MELDed material demonstrates greater corrosion resistance and greater wear resistance

• Use wire/solid bar or powder feedstock

• MELDed material exhibits low residual stress with little-to-no distortion in the printed part

• Repairs the unrepairable, welds/joins dissimilar metals

• Able to print MELDed material direct onto existing structures/components

• Repeatable process from unit-to-unit and machine-to-machine

• Surface preparation not required – see video


Programs

Discovery and Development Program

Want a first hand

experience with the additive

manufacturing technology

taking the world by

storm? This program

provides an opportunity to

MELD materials of your

choice during a program

that you direct.

What’s included:

• MELD machine

• MELD operator

• Engineering

support

• Safety training

• Dedicated

project area

Operator Certification Course

This 4-day program

provides fundamentals and

hands-on training to

develop both research and

manufacturing capability

with MELD machines. At

completion you will have a

certificate and all the parts

you made!

What’s included:

• MELD

fundamentals

• Documenting QC

• Machine training

• Tips for new

materials

• Safety training

Don’t melt. MELD.

Nanci Hardwick, CEO

[email protected]

mailto:[email protected]

don’t melt. meld.€¦ · 2019 gold winner appliedtechnology ... composites al-sic, al-fe, al-w,...

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